Mechanical Machining & Manufacturing
Our Services
Our range of mechanical processing and manufacturing services includes turning and milling operations, fine boring, grinding, honing, all types of horizontal boring mill work (up to 12 tons), as well as the production of spare parts, small batch series, prototypes, and custom components.
Using the thermal metal spraying process, we are also able to repair components such as engine blocks and cylinder heads that would otherwise be impossible to reuse—or only replaceable at significant cost and with considerable time investment.
Our high-quality manufacturing and machining equipment enables us to offer you the following services, among others:
- Refurbishment of engine blocks, engine frames, and gearbox housings for wind turbines, among other components
- Grinding of crankshafts and connecting rods
- Repair and reconditioning of cylinder heads
- Line boring of main bearing housings
- Refurbishment of cylinder liner fits with L- and Z-rings
- Production of plain bearings
- Complete overhaul of pumps for the maritime and industrial sectors
- Metal spraying using cold gas or METCO wire flame spraying processes
- Manufacturing of small series, custom-made parts, and prototypes for industrial applications
Feel free to contact us!
Grinding
Large Crankshaft Grinding
We grind your crankshafts up to a length of 6,200 mm (8,000 mm) and a swing diameter of 900 mm (1,750 mm). In addition to repairing crankshafts, compressor shafts, piston rods, or generator shafts, we also manufacture new shafts in small batches according to your specifications.
Crankshaft Inspection
Even the smallest crack can lead to severe damage. That is why, at Wulf Johannsen, crankshafts are routinely inspected using the magnetic particle inspection method. After magnetization and application of a fluorescent liquid, microscopic surface cracks become visible when illuminated with ultraviolet light.
Repair & Remanufacturing
Engine Blocks And Engine Frames
Erosion and corrosion on engine blocks and frames can be repaired using different methods depending on the type and extent of damage. In addition to the use of repair sleeves, cold spray metal coating can also be applied. This technique involves applying metal to the workpiece without the need for heating. One major advantage of this process is that it allows for the restoration not only of bores and edges but also of flat sealing surfaces on engine blocks.
We perform on-site line boring of bearing saddles worldwide, for lengths up to 12,000 mm and diameters up to Ø 480 mm. Before and after the machining process, the bearing saddles are measured using a portable laser measurement system. Even with a length of 8 meters, the measurement accuracy remains within ±0.01 mm.
With our dismountable and portable precision boring machine for bearing saddles, we are able to carry out machining at any engine location globally.
The same applies to the facing of mounting surfaces. In this area as well, our service technicians are available on-site and operate worldwide.
Metal Spraying
Cold Gas Spraying & Wire Flame Spraying
Wire Flame Spraying
At Wulf Johannsen, wire flame spraying is used to apply highly durable metallic coatings to component surfaces. This method enables the cost-effective and efficient repair of worn parts such as shafts or axles from a wide range of applications.
After spraying, the components are machined back to their original diameter by grinding or turning. Metal spraying can be performed on components up to 2,200 mm in length and with a maximum diameter of 600 mm.
Cold Gas Spraying:
Cold gas spraying involves propelling ultra-fine metal powder onto a workpiece at extremely high velocity using a carrier gas. Upon impact, the metal particles fuse into a dense metallic layer due to their immense kinetic energy – building up new metal layer by layer.
A key advantage of this process is that the components remain cold throughout, preserving their original material properties. Once the coating is applied, the metal layer can be machined as usual through milling, drilling or grinding.
This method enables the cost-efficient repair and continued use of complex and expensive components such as cylinder heads and engine blocks for large engines, other cast parts, as well as axles and shafts.
Efficient and Cost-Effective
Cylinder Head Reconditioning
Our cylinder head reconditioning service offers a cost-effective and efficient solution for the mechanical overhaul of cylinder heads, accommodating a wide range of makes and sizes.
A qualified team of specialists ensures the precise refurbishment of your cylinder heads and individual components—regardless of size—and guarantees smooth, on-time processing. From on-site disassembly through professional reconditioning and reassembly to recommissioning, all work is carried out in compliance with EN ISO 9001:2000 standards.
This service is particularly tailored to meet the demands of large engine cylinder heads, such as those found in marine diesel engines.
Plain Bearing Bushings
Gearbox Housing Repair Services For Wind Turbines
We offer gearbox housing repairs for wind turbines with a weight of up to 12 tonnes.
Our machining capabilities allow for the processing of bearing seats with a maximum diameter of 900 mm. Repairs are carried out on fully disassembled housings at our in-house workshop.
In addition, we provide cost-effective repair services for shafts and planetary axles. This enables us to significantly reduce the lead times typically associated with sourcing new components, which are often subject to long delivery periods.
Our range of services is further complemented by the supply of gears and complete bearing assemblies for your wind turbines.
Feel free to contact us!
Repair And Remanufacturing
Pumps & Pump Components
For pumps used in the maritime and industrial sectors, we offer:
- Complete overhauls and refurbishment
- Mechanical reconditioning of all pump components
- Consulting, project planning, and sales of pumps and their components
- Comprehensive service and spare parts support as a sales and service partner of renowned pump manufacturers
- Procurement and worldwide delivery of spare parts and service packages
Individual Projects
Small Series, Custom-Made Products & Prototypes
Our expertise, capabilities, and machinery from engine reconditioning are also at your service when it comes to repairing or manufacturing components for mechanical and plant engineering.