Bianchi Reparto Corse machines a wide selection of exotic alloys and materials used in the bicycle sector such as Carbon Fiber, Titanium, Aluminium and Steel.

Tubing is designed and produced according to Bianchi specifications and drawings and features reduced thickness (i.e. FG Lite aluminium 0.6 mm ), different wall gauges (1.15>0.6>0.8 ), heat treatments (steel and aluminium) and surface treatments with anti-corrosive protection. For titanium we use Shot Peening, a surface treatment which reduces breaks due to stress corrosion and/or fatigue.

Each tube features a distinct gauge, so as to maximize the geometrical and structural efficiency of the frame, keeping the weight low and maximizing performance. The material employed is accompanied by a certificate of origin declaring the chemical-physical features fixed during the design phase, to ensure quality and constant features during the production.

Bianchi pays utmost attention to the industrialization of its products: the special equipments and tools for the machining of the tubes, specially designed and manufactured, prevent the formation of micro-scratches or surface bosses during the production process.

Cutting and Milling

Starting from the geometry of each single frame, tubing is properly cut and milled. Couplings among different tubes are carried out keeping the tolerance as close as possible; the maximum gap allowed between the tube edges is of 0.1 mm. After the tubing machining, an accurate cleaning is carried out so as to obtain a welding bead which is structurally sound and aesthetically flawless. The cable guides and the cable stops are braze-welded before coupling the tubes to make up the frame, by means of welding alloys with melting point below 350°C.

Assembly and Spot-Welding

Each tube is placed on assembly jigs to ensure that all couplings are in conformity with the required specifications. If the coupling among all tubes is correct, the spot-welding is then carried out; spot-welds are small and located on the tubing sides, never along the vertical axis, which is the axis of maximum stress.

Ultrasonic washing

A state-of-the-art ultrasonic washer removes all oil residues from machining before the welding phase. The process is done by immersion, therefore the tubes are cleaned inside as well. This phase is essential for obtaining a successful weld, as well as for preventing the residues from emitting potentially toxic gases during the welding process.

TIG-Welding

Welding is carried out by means of specific alloy filler material and argon gas protection on the welding. This process prevents the melted material from reacting with the organic and inorganic compounds in the air, which could impart brittleness.

The welding phase requires a proper environment: clean, isolated and safe from drafts. This type of welding allows Bianchi to obtain the same mechanical features of the base materials. The welding beads are done in one single step thus reducing disruptions to a minimum. The starting point as well as the ending point of the welding are done on the neutral axis, never on the vertical axis. A double welding passage is never done as it would weaken tightness due to major stresses which a wider heated area would cause on the tube.

Alignment

Frame alignment is carried out after each welding phase, when the material is at its softest stage and not only at the end of the process. The frame alignment bench highlights any anomalies within one-tenth of one millimeter; these are corrected before completing the welding and continuing with heat treatments.

Heat Treatments

Heat treatments (solution, quenching and aging) are useful to give the material adequate resistance properties. The solution treatment is based on the variation of solubility at solid state of some aluminum constituents depending on the temperature. It is therefore necessary to define the temperature causing the highest solubility of these constituents and to heat up the alloy at that temperature for an optimal period of time. After the solution and quenching treatments, the aging treatment is carried out. This can be natural, at room temperature, and last some days; or it can be artificial, at a higher temperature (about 150-180°C) and last several hours. In order to get the utmost from the mechanical features before carrying out the aging treatment, the frame is kept at rest for 24 to 36 hours.

Phosphor-chromate Treatment

After the heat treatments and prior to varnishing, the aluminium frames undergo a surface protection step: phosphor-chromate treatment.