Mayville Facility
1000 Metalcraft Drive
Mayville, WI 53050
PH: 920-387-3150

West Bend Facility
2600 Metalcraft Rd.
West Bend, WI 53095
PH: 262-338-4035

Beaver Dam Facility
2020 N. Spring
Beaver Dam, WI 53916
PH: 920-887-4395


Metalcraft Tank Manufacturing

  • Commitment in sharing DFM ideas with customers to drive out cost
  • Dedicated tank value stream with high level of automation
  • Numerous robotic and manual welding cells
  • State of the art leak test chamber and tank cleanliness
  • Capable of supplying tanks at the highest assembly level
  • Partner in tank system design and development
  • 99% on-time delivery

rfq’s – Customer design with dfm collaboration

  • Commonly achieve 10% - 30% cost reduction from original design
    • Utilize common materials and bend radii on formed parts
    • Reduction of overall weld inches
  • Faster speed to market as less pilot trials are required
  • Objective of getting it right the first time
  • Best in class tank cleanliness and leak test validation
    • Focus on improving cleaning & drainage to achieve required cleanliness
    • Zero leaks at assembly or in the field
  • Our fast, flexible, and reliable approach enables the Metalcraft team to pursue making your project a success

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Tool design/ build capabilities

  • Up front collaboration with customers and Metalcraft team for DFM opportunities
  • In house collaboration with manufacturing and engineering to determine process
    • Customer models imported into WeldPro© to determine torch access, part positioning and cycle time balancing
    • Identification of critical characteristics to determine special tooling requirements
      • Manufacturing jigs
      • Functional gages
      • Form tooling
      • Material handling equipment
  • In house tooling design and build
    • Tool design in Creo© using customer models
    • Adjustability designed into tools to facilitate fine tuning and to overcome heat distortion
    • Use of hydraulic clamping for tool automation and improved process times
    • Rapid response to revision changes
  • Tool and part models imported into WeldPro© for off-line robot programming
    • Identify possible torch access and interference issues
    • Shortens lead time

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Leak testing – sniffing tracer gases

  • Challenges of immersion testing motivated the Metalcraft technical teams to look for another solution
    • Limitations of immersion testing
      • Low test sensitivity
        • Only capable of detecting leaks effectively in the 10-2 atm-cc/sec leak rate range
      • Difficulties maintaining clarity of water
      • Opportunities for rust
      • Increased material handling
        • 100% inspection of weld seams requires part rotation
          • Agitation of water during rotation increases difficulty to locate leaks
      • Inconvenience of wet parts
      • Manual operation - opportunities for human error
  • Sniffing with tracer gases using mass spectrometers resolved many of the immersion test issues
    • 100% inspection of weld seams without additional material handling
    • Increased sensitivity, accuracy, and efficiency
      • Calibrated leaks installed on units ensures readings are accurate
    • Tracer gases used
      • 95% nitrogen/ 5% hydrogen mix
        • Low cost and readily available
        • Increased sensitivity due to lower gas atomic masses and viscosities
        • Capable of pinpointing leaks into the 10-5 atm–cc/sec leak rate range
      • Helium
        • Maximizes sensitivity
        • High concentration paired with its atomic mass and viscosity provides the ability to detect small leaks into the 10-7 atm-cc/sec leak rate range
        • Virtually no background noise to compromise validity of test
          • Very small amounts of helium are present in the atmosphere
    • Limitations of sniffing with tracer gases
      • Manual operation - opportunities for human error


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Leak Testing - Helium vacuum chamber

  • Helium vacuum leak testing chamber - pass/fail test
    • Part and vacuum chamber pump down to 0 PSIA
    • Part is backfilled with helium to part specification
    • Helium leaking from part is measured using integrated global mass spectrometer
    • Part passes or fails depending on measured leak rate and leak rate rejection set point
      • Failed parts leave chamber pressurized with helium and are manually sniffed to pinpoint leaks for repair
  • Advantages of helium vacuum chamber
    • Automated test – eliminates opportunities for human error
    • Integrated database using part serialization to track test history
    • High concentration of helium allows for maximum accuracy
      • Integrated helium recovery system allows testing with high helium concentrations to be cost effective
    • Versatile programs can be adjusted to fit any customer specified PSI limits or leak rate specifications
    • Ability to test large parts at a high level of sensitivity
      • Chamber dimensions: 118”Lx 81”W x 62”H
        • If part exceeds chamber dimensions
          • Dye penatrant
          • Pressure decay test
          • 95% nitrogen/5% hydrogen sniff

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Continuous Process Improvement

  • Leak location data is collected at each leak testing operation to track leak performance which is then and is charted to determine root cause and drive corrective action plan
  • Leak locations are analyzed by quantity and percentage of parts with given leaks
  • Leak locations with highest occurrence receives focused improvement efforts
    • DFM (Design for Manufacturing)
    • Robotic programming adjustments
    • Weld fixture adjustment
    • Component consistency verification
    • Standard work instruction for manual operations
  • Improved areas are tracked to validate and control the improved performance

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cleaning/ validation systems

  • Automated cleaning stations and dedicated hanging bars
    • Ensures each tank is cleaned the same way every time
    • Ensures that ever tank is hung in the best position for cleaning and draining
  • Automated tank flushing equipment for cleanliness validation
    • Tanks are flushed while hung in the same position as they are washed
      • This allows the tank to be accurately flushed to ensure all remaining debris can be extracted for gravimetric evaluation
      • The system runs the extracted material straight to a filter for evaluation
      • This eliminates opportunities to lose some of the captured material, while giving a more accurate measurement of tank cleanliness.

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Assembly/ Secondary leak TESTING

  • Capability to leak test assembled components before shipment
  • Value added assembly for line ready production

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