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time that it is a car that is being created here. A wonderful example of how the engineers pay heed to the material characteristics of aluminum are the flow drill screws, which fix the floor sheets and are handled by one of the two robots: an automatic screwdriver is attached to its arm, and air pressure turns the screw securely into place. It lets its top rotate on the sheet, which does not have any pilot holes, creating temperatures of about 200 degrees Centigrade. As a result, the aluminum softens, the screw enters the sheet, furrows into the screw thread, and the electronic control system provides a torque of exactly seven Newton-meters. THE CAR BODY SHELL IS CHECKED PAINSTAKINGLY The sheet metal specialists attach the car body shell to the frame: fender by fender, panel by panel, the Lamborghini’s racy silhouette becomes visible. Once again, a lot of riveting is carried out, but welding torches also light their splicing fire on the light metal. Whatever seam it leaves behind is initially filed away, and body specialists ensure the final polish: Even the tiniest unevenness is sanded down; expert grinders feel the surface carefully with their gloved hands and then use their tools to remove miniscule amounts of excess aluminum. At last, a totally even surface can be seen where only a short time before the seam was still clearly visible. After all these production steps, each body in white is checked to ensure that all measurements are in line with Lamborghini’s specifications, and to this end the future sports car is briefly lifted up and TK Magazine | 1 | 2004 | The Lamborghini Gallardo is an undisputed star on the streets and stradas of this world. Five-hundred horse power propel it to 100 km/h within just four seconds; its lightweight body helps, of course. GALLARDO 73 fitted into the “teaching vehicle,” which meets the exact measurements. Any deviations are adjusted – though this is rarely necessary at this stage. Testing of the bodies becomes more sophisticated all the time; already, a sophisticated sensor spends four hours feeling thousands of points and comparing them to the computer data in the measuring space. But the Lamborghini torso is not yet complete: next stop is the finishing process, where the body is polished to absolute evenness with a very fine abrasive in a separate room with optimal lighting and a fine dust extraction system. The people working here are at the very top of their field, since not everyone can develop the sensitivity and visual judgement necessary to determine where another trace of metal has to be removed or where another very slight tap with a hammer is needed to obtain the perfect surface. And one learns that “even” is sometimes not even enough, for the first painting mercilessly exposes even the smallest unevenness. Confident at last that everything has been done so that another Gallardo body will meet this exacting test, ThyssenKrupp Drauz ships it to the paint shop at Audi, from where it will travel to a factory in Sant’Agata in Italy. There, the Gallardo is fitted with its powerful motor and everything else that is needed to make a true Italian sports car – a vehicle that can perform brilliantly on the streets and stradas of this world and look great doing it. A product of top technology and superior craftsmanship all packed inside a visually stunning, aluminum body. 7
74 RINK ‘GLASS’ Ice hockey is the fastest, and one of the toughest, team sports in the world. For fans, watching a game from the front row is the greatest experience of all By Benedikt Breith | Photos Andreas Möltgen A shield that lets through the emotions It’s the speed that excites – speed that at times seems beyond human capability. Just as exciting, however, is the danger – a danger that people seek out, knowing they are safe. We’re talking about ice hockey rinks and one particular rink, specifically the Düsseldorf Eislauf Gesellschaft (DEG) stadium, which has been known for decades for the lively atmosphere created by the local team’s fans, whose creativity, sayings, songs and heartfelt but restrained emotions are legendary. With good reason: in this stadium, fans and players are very close to each other. Close in a game whose speed is fascinating but also creates the greatest potential danger. PLASTIC PROTECTION FOR THE AUDIENCE After all, the puck, which is a kind of stone of the wise in ice hockey, deciding triumph and disappointment, reaches a speed of 180 kilometers per hour. If a person is hit by such a shot – traveling 50 meters every second – it could be fatal. Therefore, preventive measures are taken at TK Magazine | 1 | 2004 |
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magazine TK Think. Think it over. T
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2 CONTENTS 12 Sparklers bring a lit
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4 BOBSLEIGH RACING Susi Erdmann is
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6 BOBSLEIGH RACING Taken to extreme
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8 BOBSLEIGH RACING
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10 BOBSLEIGH RACING The bobsleigh c
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12 SPARKLERS Iron powder for golden
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14 SPARKLERS
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16 SPARKLERS Sparklers with a bouqu
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18 SPARKLERS STICHWORT Perhaps the
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20 Y SLEEPERS
Page 23 and 24: 22 Y SLEEPERS
Page 25 and 26: 24 Y SLEEPERS
Page 27 and 28: 26 STICHWORT Y SLEEPERS The home of
Page 29 and 30: 28 Y SLEEPERS on this Y sleeper sys
Page 31 and 32: 30 ASSEMBLED CAMSHAFTS To anyone wh
Page 33 and 34: 32 OIL TOOLS
Page 35 and 36: 34 OIL TOOLS A “power slip” has
Page 37 and 38: 36 OIL TOOLS
Page 39 and 40: 38 CAB DESIGN
Page 41 and 42: 40 CAB DESIGN If the side walls are
Page 43 and 44: 42 MASTER BUILDER
Page 45 and 46: 44 MASTER BUILDER She looks very el
Page 47 and 48: 46 MASTER BUILDER
Page 49 and 50: 48 LiDONIT By Sebastian Groß | Pho
Page 51 and 52: 50 LiDONIT
Page 53 and 54: 52 LiDONIT the earth slowly and ove
Page 55 and 56: 54 NEWSTEELBODY
Page 57 and 58: 56 NEWSTEELBODY tional auto bodies.
Page 59 and 60: 58 INTERVIEW
Page 61 and 62: 60 INTERVIEW above all, who decides
Page 63 and 64: 62 EDWARD G. BUDD
Page 66 and 67: EDWARD G. BUDD 65 superior to a woo
Page 68 and 69: TK Magazine | 1 | 2004 | EDWARD G.
Page 70 and 71: TK Magazine | 1 | 2004 | GALLARDO 6
Page 72 and 73: TK Magazine | 1 | 2004 | The motto
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Page 78 and 79: exotic applications that Eschbach d
Page 80 and 81: Metal materials - and the man who k
Page 82 and 83: MATERIALS SELECTION 81
Page 84 and 85: Jochen Adams is a pragmatic man who
Page 86 and 87: Laser welding requires special stee
Page 88 and 89: Laser imprint without tolerance sun
Page 90 and 91: The Unna plant has only been operat
Page 92 and 93: must be no mix-up, so not one of th
Page 94 and 95: The corrosion resistance of stainle
Page 96 and 97: The lightweight among basic materia
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Page 100 and 101: duce a car’s weight by about 100
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Page 106 and 107: OBERRIED 105 Safe from all the elem
Page 110 and 111: sources of disturbance. Even if no
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