Malben Engineering invests in technology step-change

Welding is integral to the automotive manufacturing process. Malben Engineering, an award-winning

supplier of high-level welded assemblies to both Original Equipment Manufacturers (OEMs) and tier
1 automotive sector suppliers, has invested in a massive technical step-change over the past three

years.

Operational Director Luca Smargiasso says the introduction of a new vehicle model by a key
customer necessitated the introduction of new, completely automated welding technologies. These
include adaptive pulse welding, DC projection welders and controlled voltage spot welders; as well
as advanced variable pulse MIG welding technology.

Malben Engineering’s rigorous welding production processes, backed by extensive quality controls,
deliver an impressive 750 000 projection welds and 1.7 million spot welds monthly. The company is
furthermore compliant with the automotive sector’s CQI 15 quality standard – and was one of the
first tier 1 suppliers to achieve A-rating and green status – maintaining a zero margin for defects
and a rejection rate of zero parts per million (PPM), significantl

y exceeding customer expectations.

Although Malben has welded both coated and uncoated mild steel automotive parts for decades,
Smargiasso says that the automotive industry is using thinner gau

ge, higher tensile steels, which

makes welding more challenging: “There is a drive to go thinner with stronger materials, to reduce
weight and improve fuel efficiency.” The advantage of Malben’s automation and attention to detail is
predictability and consistency, which go hand-in-hand: “In our sector, we are doing production
welding for mass production runs. So, our welds must be exactly the same – every time,” explains
Quinten Ballot, Head of Maintenance who has extensive welding experience.

Over the past eight months, Malben proudly reports zero rejections. Smargiasso explains: “It is like
climbing a mountain. Everybody can do day one, most people can do day two – however from day
three, they cannot continue and are in danger of falling! It is being able to do the same thing day in,
day out – over an extended period and without letting your guard slip – which really counts.”

The real-time control of weld parameters is achieved by using pulse welding: “The welding
parameters are adjusted in real-time during the weld process. If the gap between the welded parts
varies due to dimensional tolerance allowances, the weld voltage and arc length are adapted
accordingly.

Technical Director Marco Smargiasso says that an important part of the Malben step-change was a
move from AC to DC, with the move to DC projection welders – noting that that where robotic spot
welders are still controlled by AC, this is carefully checked: “We monitor and measure the voltage. If
there is something wrong, it is immediately stopped. Monitoring current ensures we do not get a
cold weld.”

Ballot observes that the quality welding which Malben achieves, also relies on highly skilled team
members. “Malben not only employs experienced welders – but actively builds skills within the
company to keep pace with technology, and most importantly, with the requirements of our valued
customers,” he concludes.