Ultra-precise aluminium piston rods, precision rods and tubes incl. machining and hard anodising
GerostAL GmbH
Kerpen (headquarters, manufacturing, sales)New on Amplifa
The Company
GerostAL GmbH was founded in 2006 in Kerpen by Rolf Raue, Gerald Müller and Stephan Fels and specialises in aluminium. Its core task is the development and manufacture of ultra-precise aluminium piston rods of the FeramAL 7075 brand made from EN AW 7075 T6, whose process has been registered as a utility model. The process combines ring compaction of the edge zone with hard anodised coating and mechanical grinding. In addition, tightly toleranced aluminium precision round rods, precision round tubes, pneumatic round tubes, ISO cylinder tubes and drawn profiles are supplied as semi-finished, pre-machined or ready-to-install components. Machining services include sawing, milling on 3- and 5-axis bar machining centres, centreless cylindrical grinding as well as milling of plastic sheets. A third business area covers mechanical engineering and construction profiles including design, assembly and on-site installation. Customers come from general and special machinery construction, pneumatics, hydraulics, linear guide technology and medical technology.
- Site
- Kerpen
- Processes
- Manufacture of FeramAL 7075 aluminium piston rods (ring compaction, hard anodising), Manufacture of aluminium precision round tubes (hard anodised, ground layers), Manufacture of aluminium precision round rods (hard anodised, ground layers), Milling (3- and 5-axis bar machining centres), Milling on gantry milling machine (Makrolon and hard plastic fibre sheets), Sawing (aluminium circular sawing machines, burr-free), Centreless cylindrical grinding (fine grinding of aluminium rods and tubes), Surface coating (hard anodising/hard coat anodising, also black-coloured HC layers)
- Materials
- FeramAL 7075 (aluminium piston rods, EN AW 7075 T6, AlZn5,5MgCu), Aluminium (general, precision round rods/tubes), Stainless steel (piston rod reference material), Makrolon (fibre sheets for gantry milling machine), Hard plastic fibre sheets, FeramAL 7075 (EN AW 7075 T6, AlZn5,5MgCu), Aluminium (precision round rods/tubes), Stainless steel
- Certificates
- ISO 9001:2015, ISO 45001:2018, ISO 14001:2015, ISO 9001, ISO 14001, ISO 45001
- Founded
- 2006
- Employees
- 17
- Industries
- General and special machinery construction, Pneumatics, Hydraulics, Linear guide technology, Medical technology
- 01
Design (3D CAD)
- 02
Procurement/cutting of aluminium semi-finished stock
- 03
Sawing
- 04
Milling
- 05
Centreless cylindrical grinding
- 06
Ring compaction (FeramAL)
- 07
Hard anodising
- 08
Deburring and packaging
- 09
Assembly/on-site installation
- 10
Delivery with own vehicle fleet
Materials & Processes
FeramAL 7075 (EN AW 7075 T6, AlZn5,5MgCu)
High-strength aluminium piston rods with ring-compacted edge zone and hard anodised layer for pneumatics, hydraulics, gas springs and linear guide technology.
Aluminium (precision round rods/tubes)
Drawn round rods and round tubes with hard anodised, ground layers (layer thickness at least 25 µm, Rz ≤ 1).
Stainless steel
Reference material for comparing piston rod properties against steel rods.
Makrolon
Fibre sheets for machining on the gantry milling machine.
Hard plastic fibre sheets
Machining on the gantry milling machine up to 1,000 x 800 mm.
Sites
Kerpen
DEHeadquarters, manufacturing, sales
- Lot size
- 1 – 10.000 units
- Materials
- Aluminium (EN AW 7075 among others), plastics
- Bar machining centre 122/71 SBZ (3-axis, max. 4,150 mm)
- 3x bar machining centre 122/75 SBZ (5-axis, max. 3,851 mm)
- Gantry milling machine (1,400 x 800 mm, repeatability 0.01 mm)
- Aluminium circular sawing machine (fully automatic)
- Aluminium circular sawing machine (semi-automatic)
- 4x centreless cylindrical grinding machines (Ø 6 – 60 mm)
- 3D CAD workstation
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of FeramAL 7075 aluminium piston rods (ring compaction, hard anodising)Surface | up to h6 (optional), h8 (standard) · Rz ≤ 1 (optional), Rz ≤ 3 (standard) | – | – | – | EN AW 7075 T6 |
| Manufacture of aluminium precision round tubes (hard anodised, ground layers)Surface | Tolerance classes for unit shafts of grades 7 to 9 · Rz ≤ 1 | 3000 mm +/-100mm | – | – | EN AW 7075, other aluminium alloys |
| Manufacture of aluminium precision round rods (hard anodised, ground layers)Surface | Tolerance classes for unit shafts of grades 7 to 9 · Rz ≤ 1 | 3000 mm +/-100mm | – | – | EN AW 7075, other aluminium alloys |
| Milling (3- and 5-axis bar machining centres)Machining | Positioning accuracy +/-0.1 mm | 4,150 mm (3-axis) / 3,851 mm (5-axis) × 280 mm | – | – | Aluminium |
| Milling on gantry milling machine (Makrolon and hard plastic fibre sheets)Machining | Repeatability 0.01 mm | 1,000 mm × 800 mm × 104 mm | – | – | Makrolon, hard plastic fibre sheets, Aluminium |
| Sawing (aluminium circular sawing machines, burr-free)Machining | tightest tolerances | 160 mm (standard production range) | – | 1 – 10,000 | Aluminium |
| Centreless cylindrical grinding (fine grinding of aluminium rods and tubes)Machining | Tolerance grades 7 – 10 | Diameter 6 mm – 60 mm | – | – | Aluminium |
| Surface coating (hard anodising/hard coat anodising, also black-coloured HC layers)Surface | – | – | – | – | Aluminium |
| Trading/semi-finished products | tightly toleranced | 4 m | – | 1 – 10,000 | Aluminium |
| Assembly | – | – | – | – | Aluminium |
| Design (3D CAD workstation, drawings for quotation and design, bills of materials)Engineering | – | – | – | – | – |
| Assembly | – | – | – | – | Aluminium |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Bar machining centre 122/71 SBZ (3-axis) | 122/71 SBZ | 1 | – | – | Kerpen |
| Bar machining centre 122/75 SBZ (5-axis) | 122/75 SBZ | 3 | – | – | Kerpen |
| Gantry milling machine | – | 1 | Travel X 1400 mm, Y 800 mm, Z 110 mm; max. workpiece height 104 mm; spindle max. 40,000 1/min | – | Kerpen |
| Aluminium circular sawing machine (fully automatic) | – | – | – | – | Kerpen |
| Aluminium circular sawing machine (semi-automatic) | – | – | Saw blade diameter 500 mm, 2,800 1/min; production range up to 160 mm | – | Kerpen |
| Centreless cylindrical grinding machine | – | 4 | Diameter 6 mm – 60 mm | – | Kerpen |
| 3D CAD workstation | – | 1 | – | – | Kerpen |
Additional services
Reference customers
Quality
The management system is certified according to ISO 9001, ISO 14001 and ISO 45001 (since March 2019, without deviations, SGS). Quality assurance includes, among other things, metallographic cross-sections performed by an independent testing laboratory; the complaint rate has been low for years.
| Evidence | Kerpen |
|---|---|
| ISO 9001 | |
| ISO 14001 | |
| ISO 45001 |
History
- 2006
Foundation of GerostAL GmbH by Rolf Raue, Gerald Müller and Stephan Fels; development and manufacture of ultra-precise aluminium piston rods, utility model registration of the manufacturing process, brand name FeramAL 7075
- 2012
Addition of the mechanical engineering/construction profiles business area, investment in a 3D CAD workstation
- 2019
First certification according to ISO 9001, ISO 45001 and ISO 14001 in March 2019, without deviations