Always one gear ahead
Diehl Metall is a successful partner to the international automotive industry in the area of synchronizer ring production. The company develops and produces high-performance brass and steel synchronizer rings for all application areas. Our products fulfil exacting requirements with respect to precise geometry, high wear-resistance and strength.
Customized solutions for every application
Diehl Metall offers a wide selection of innovative friction layers for brass and steel synchronizer rings. These generate stable friction and wear behavior under various and even extreme loads.
For modern high-performance transmissions, we primarily develop synchronizer rings with carbon layers of the brand Diehl BlackLine. Compared to commonly used friction layers, these offer considerable advantages in terms of service life.
The advantages at a glance:
- Maximum performance and overload capacity
- Outstanding oil compatibility and wear resistance
- Customized solutions at a cost-efficient and technical level
The lightness of steel
We recommend steel synchronizer rings particularly for use in high-performance transmissions. Depending on customer requirements, the steel synchronizer rings undergo various heat treatment processes. If required, we can offer the synchronizer rings with ground friction surfaces.
With a large range of friction layers, we offer high-performance synchronizer rings for all application areas.
- Production process
Steel synchronizer rings are produced by means of sheet-metal forming. Progressive and transfer tools are used on our stamping and forming machines, which have a pressing force of up to 8000 kN. Depending on the requirements, various process steps are carried out in these tools, such as stamping, coining, bending and joining operations.
In sheet-metal forming the following alloys are processed. By means of a specially developed nitriding process, the finished parts demonstrate hard, wear-resistant rim zones and, at the same time, a high level of ductility at the core.
Diehl Metall DIN EN DIN EN Symbol [Material Number] State Mechanical Properties Rp0.2 [MPa] Mechanical Properties Rm [MPa] Vickers Hardness 16MnCr5 1.7131 nitrated > 380 < 460 > 600 HV0.5 C35E 1.1181 nitrated > 420 < 500 > 300 HV0.5 C75S 1.1248 quenched and tempered < 1200 < 1500 > 500 HV10 HC260LA 1.0480 nitrated > 340 < 440 > 300 HV0.5
Standard value - Young's modulus E = 210,000 N/mm²
Standard value - Poisson's ratio Ʋ = 0.3
- Sheet-metal forming know-how
Our know-how and the continuous further development of cold forming technology in terms of customer orientation and cost-efficiency allow us to push the limits of what is possible. Our expertise ranges from all aspects of sheet-metal forming technology to the production of net-shape products:
- Product development
- Part design
- Tool design
- Tool manufacture
- Cold forming
The resistance of brass
Due to their unrivalled price-performance ratio, uncoated brass synchronizer rings with friction threads of the brand Diehl GoldLine represent the standard solution for all passenger car transmissions.
The continuous further development of the alloys allow us to offer efficient solutions even for modern transmission oils. Furthermore, innovative friction layers enable the use of brass synchronizer rings in highly loaded transmissions.
- Production process
Diehl Metall has an integrated value-adding chain in the production process of brass synchronizer rings.
Thanks to our in-house expertise, for instance in development and tool manufacture, we can offer short product development times from the RFQ to on-time delivery.
The foundation for needs-based products
In the area of material development, we design in-house patented high-performance brasses for synchronizer rings. With our broad range of alloys, we are already taking into account the future requirements of EU guidelines for end-of-life vehicles, for instance with our lead-free special brasses.
Proximity to our customers and the alignment of our development activities to their goals are of utmost importance to us. We support new projects with our know-how, always with a view to the desired goal.
- Research & Development
Ideas for customer success
Diehl Metall has its own in-house Research & Development Center, including its own state-of-the-art laboratory. This allows us to provide our customers with full support as early as the product design phase and during the production process. For instance, we provide advice on selecting the materials suited to the application or on ways of achieving an optimized design in terms of the forming process.
Here, we focus in particular on the development of synchronizations for automotive manual and dual-clutch transmissions.
Know-how put to intelligent use
The service spectrum of our laboratory encompasses various material analyses on samples, semi-finished goods and components. The aims of these analyses include determining mechanical and physical values or assessing microstructure properties, for instance. Furthermore, we carry out special analyses as part of development projects and advise customers on all issues relating to materials. The following recognized testing processes are used:
- Hardness testing (Brinell, Vickers, Rockwell) und micro hardness testing
- Tensile and compressive tests
- Metallography (microstructure analysis, corrosion test, coating assessment)
- Quantitative microstructure analysis (image analysis system)
- Scanning electron microscope
- EDX microanalysis (spot measurement, surface scan, spectral mapping)
- Chemical analysis
- Technical cleanliness
- Tool manufacture
Independent manufacture and modification
We develop, design and manufacture all tools for forging, machining and forming as well as all gauges and fixtures in-house. To do so, we use modern CAD/CAM systems and production processes, such as erosion and 5-axis high-speed milling. These ensure high-precision and cost-effective tool production. With computer-aided systems for forging simulation (FEM) we determine material flows, tool load and the characteristic values of individual process steps.
- Test benches
Diehl Metall offers testing at all stages – from material and component tests to service life and functional tests in the transmission. Various test benches are used:
- Component test benches for frictional value, wear and system function
- Transmission test benches
- Dynamic testing machines for strength analyses
- Quality management
Quality Management – Committed to Quality
Diehl Metall has a certified quality management system according to international quality guidelines. This guarantees the high standard of quality of our products and services in the entire process – right from the initial product idea. We consistently determine customer requirements and are committed to a zero-defect strategy. After all, the measure of our success is the satisfaction of our customers.
- Quality: IATF 16949 and ISO 9001
- Environment: ISO 14001
- Energy: ISO 50001