Recovery Technology
Continuous improvement and constant innovations are essential to our
business philosophy. Detroit Diesel Remanufacturing not only restores
damaged products, but rejuvenates the product to its original blueprint
specification while incorporating the current engineering upgrades.
One
of DDR's advanced capabilities is to restore the materials of worn
surfaces. Processes such as metal flame welding and flame spraying
enable us to return the product to its original dimensions and ensure
that no "oversized" components are used.
- Basic Welding
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Standard TIG and MIG welding are commonly used to repair and recover components.
Pictured: Recovery of an aluminum 2-cycle blower rotor. It will be machined back to original specification for maximum blower efficiency.
- Thermal Powder Spray Process
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The thermal powder spray process has been used for over 15 years to rebuild worn or damaged aluminum and cast iron surfaces. This process allows us to recover a wide variety of components, including some that are no longer available as new parts.
Pictured: A 2-cycle aluminum blower housing.
- Submerged Arc Welding
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Submerged arc welding is an automated welding process that is used to rebuild metal in thicker quantities. The process is able to be done in the open due to a flooding of flux over the actual weld process. This process is very useful in recovering non-wear areas that have incurred damaged on the surface.
Pictured: Recovery of a crankshaft snout.
- Twin Wire Process
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The twin wire process is similar to the powder spray process but it uses two wires as the base coating material instead of powder. The wires are atomized using an electrical charge and a pressurized inert gas is used to apply it on a surface. The twin wire process is becoming more popular in our remanufacturing processes as it is more versatile than powder spray.
- Supersonic Spray
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Used to make cosmetic repairs to aluminum and cast iron. The process applies metal at a high velocity and introduces very little heat into the base component. It allows us to fix small flaws in components.
Pictured: A cylinder head being repaired using supersonic spray technology.
- Plasma Transferred Wire Arc
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An extremely versatile surface coating technology. This process uses a single wire and a small application head to coat hard to reach areas. The surface can be honed back to the original specification used on a new block.
Pictured: A gas engine cylinder bore being coated with a low cost wire.
Steps of the Reman Process
1) Disassembly and inspection
First, we completely disassemble the unit to its core assemblies. Unsalvageable parts that don't meet our strict core quality guidelines are scrapped.
2) Parts Recovery
Salvageable non-wear parts that meet the quality standards are cleaned and reconditioned to meet rigid OE blueprint specifications. We choose the best recovery method for the job, and all of our recovery processes have been qualified by our engineers using extensive metallurgical analysis, long term durability testing, and field testing.
3) Assembly Line
From here the process looks just like the original manufacturing process. The recovered parts are placed on an assembly line along with the required new parts (bearings, seals, etc.).
4) Quality Testing
Once assemblied, the unit is fully tested by the same kind of quality testing used for brand new parts.
