Metal Flow: value-added assemblies

Value-added assembly examples

Oxygen sensor
Spark plug shield
Fuel injector cups
Bead lock connector
Fuel filler neck plunger

Metal Flow pursues every opportunity to provide additional value to our customers. Utilizing our transfer presses and custom designed tooling, Metal Flow offers multiple forming operations within one tool, transforming multi-piece assemblies into single part components. Expensive machining operations are replaced with a drawn component, saving time and reducing cost. We add value through secondary operations like roll grove forming, bending, welding, beading, grinding, part cleaning, and vibratory deburring.

Oxygen sensor
Oxygen sensors are used in the fuel metering system for exact control of the combustible air-fuel mixture. Metal Flow has produced millions of oxygen sensor components. In the photograph the oxygen sensor assembly is shown above Metal Flow's drawn parts. Inner and outer shells are made of 304L stainless steel. All holes are pierced in the press, parts are washed, and both components are spot welded within a closed loop cell operation.

Spark plug shield
The spark plug shield assembly is shown above center. Metal Flow draws the shell, inserts the spring and contains it in position, parts are washed, tumbled and dried and dual rotary tables insert the die electric barrier paper element. All dimensional tolerances are checked via sensoring and parts are packed in returnable containers at the press. This high volume assembly operation reflects a core capability for Metal Flow.

Fuel injector cups
Metal Flow produces millions of stainless steel, very tightly toleranced fuel injector cups that are used in numerous fuel rail applications. Working closely with our customers' engineers our drawn metal components provide them with the piece of mind that the fit, finish, and quality of our products meet their stringent requirements.

Bead lock connector
This application is a bead lock connector for fuel lines. Metal Flow forms both of these components in the same press rather than using two separate presses and assembling as a secondary operation. By optimizing all the stations of the press and eliminating a secondary assembly operation we save our customer time and money.

Fuel filler neck plunger
This three piece assembly Metal Flow produces is made-up of an inner and outer shell with a spring loaded end. This application is used in the fuel filler neck assembly to prevent fuel from escaping the vehicle in the event of a rollover accident.

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