All the research and experience acquired over the years has enabled us to be equipped with state-of-art high tech CNC machines produced expressly to guarantee working precision
and flexibility in production. The main components of each gun (the actions, both in steel and light alloy, the forend irons, the monoblocks, the triggers guards and extractors) are all made from solid forgings, meaning that the material fibers are not cut in any way by tools, therefore the resistance of the material
All the actions in steel (16NiCrS4) are submitted to a casehardening treatment guaranteeing an internal flexibility inside the action core, leaving a very hard surface.
All the actions in Ergal 55 are made from solid forgings and are controlled with a system of liquid penetrants. They are specially treated with a shiny, silver nickel plating or, alternatively with a special Tinaloid treatment (black nickel) or ruthenium (grey nickel).
Both treatments, besides being both aesthetically beautiful, are extremely effective against rusting.
All components are machined on the latest state-of-the-art CNN machines and a well equipped metrological room allows measurement and tolerance control.
The monoblocks are made in special steel (42NiCrMo4) and are appropriately monitored during the entire productive process through ultrasonic and surface verifications for internal imperfections. The extractors are made from hardened steel (39NiCrMo3) and are machined on horizontal CNC machines using micrograin solid carbide tools.
THE BAR PROCESSING
Production cycle of barrels starts from steel bars that have been made according to the standards set out by the specifications given by the University of Mechanical Engineering in Brescia. This standard is the result of a series of analysis and tests carried out on samples of steel bars with different thicknesses in such to correspond to gun barrels of different
calibers. This is done with the intention to evaluate and determine the safety limits in comparison to distortion and, therefore, to determine the specifications for the production of the appropriate steel. With every supply of steel, a sample is taken out, listed and then stored for a period of 6 months for an eventual follow up.
The original length of the bars is 5 metres. The bar has to be cut and drilled to the indicated measurement and, by means of a reamer, given the internal diameter.
At this point the exterior is still rough, therefore the next job is to machine turn to allow the next stage which is to cold hammer the internal chokes. After hammering, the barrels have to undergo a second stage of processing to achieve the external profiles with relative coupling up of the monoblock. Verification checks are carried out on the dimensions and the straightness of the tubes. The strength of the production cycle is the achievement of the outside profile of the tubes through the use of particular CNN machines that allow every type of profile.
Next is the pickling treatment which is completely computerized and in a closed circuit thus respecting the environmental regulations and, at the moment, unique in its kind. With the pickling treatment, we proceed to eliminate all excess alloy through electrolysis. This “avantgarde” process perfectly cleans the barrels without weakening the structure in any way.
After the pickling treatment has been carried out, the barrels are inspected to make sure the welding has been executed in every part. Then, to the final stage of internal lapping of the barrels.
The following finishing stages of the barrel include the cartridge chamber (also reamed and lapped), internal barrel chroming and, following, the mirror polishing. Then we come to the stage of the rib chequering, straightening, external polishing
of the barrels and, finally, blueing. Once the production cycle is terminated, the borders are engraved.
Finally the markings requested by the National Proof House and, also those requested by the customer, are laser engraved on the barrel.
Next, a first dimensional check is carried out on the piece and the exterior of the tube is lapped.
We are now at the stage where the components have to be manually bound together. The people involved in this procedure have a learned experience and, assisted by special toolings, proceed to assemble the various accessories that have to complete the barrel: top and side ribs, lugs and belt rings, ready to be assembled in a predetermined position that will allow the welding.
Welding, in fact, is an important step because it unites for ever all the elements to get a complete pair of barrels.
Welding is carried out in controlled atmosphere ovens (with the use of a brazing alloy with a silver base) at a low melting point so the features of the material are not modified.
Strict verification tests are carried out on the temperatures, monitoring the various stages of welding to get the best results.
Drilling these barrels benefits from a context of progressive cone construction where the first section is super bored at 18,7mm for a section of 20 cm determining a minor acceleration of outgoing shot and, consequently, a smooth expansion of pressure with consequent recoil reduction. The second is a progressive section where the bore of the barrel goes from 18,7mm to 18,4mm significantly favouring the increase of velocity. The last section is comprised of a choke in case the barrel has fixed chokes or the housing for interchangeable chokes. The reduced angle of the taper, therefore, prevents the radial thrust of steel shot thus preventing any possible damage to the barrel, especially in those with fixed choke that are able to maintain also full choke. The Dual Cone barrels, therefore, have a remarkable advantage of compactness of the pattern cone, more range and, not to be considered as less important, a considerable reduction of recoil.