Morgan Technical Ceramics (MTC) showcased pre-sintered preforms (PSP) produced by its Wesgo Metals manufacturing site in Hayward, California, at the MRO AMERICAS 2011 Conference and Exhibition, April 12-14, 2011, Miami Beach Convention Center, Miami, USA. On display were samples of MTC’s newest PSP dimensional capabilities, which include significantly larger and thinner sheets.
PSPs are a sintered metallurgy product composed of a customised blend of brazing and superalloy powders. They are available in various shapes and compositions, and are ideal for high temperature applications in the aircraft maintenance, repair and overhaul (MRO) industry. PSPs can be used for crack repair and dimensional restoration of aero-engine components such as turbine blades and vanes.
For customised applications, MTC offers PSPs in various compositions and shapes, with plate thickness ranging from 0.010-inch (0.3mm) to 0.060-inch (1.5mm). An innovative new process has recently extended the range of thicknesses available to 0.200-inch (5mm). The preforms are cut from the sintered plate, tack welded to a component and vacuum brazed. PSPs are also available in pastes and paints, which are ideal for difficult-to-reach areas.
“MTC is flexible, adaptable and responsive, which enables us to develop tailor made solutions for customers around the world,” said Mark Miklos, general manager for Morgan Technical Ceramics – Wesgo Metals. He added, “Our California operation has direct access to the latest technology and global inter-company sourcing offered by one of the world’s leading advanced materials companies, which enhances our strength. In addition to our local manufacturing capabilities, we can respond to customer supply chain requirements, including just in time shipping and vendor-managed inventory.”
Many OEMs and repair facilities depend on PSPs to rebuild the contours of turbine blades and vanes. MTC’s PSPs provide selective build-up of the part, saving time, enhancing cost-effectiveness and avoiding the distortion associated with welding.
With turbine temperatures reaching up to 1300°C and the presence of hot corrosive gases, aero-engine components face extensive wear. Rather than purchase expensive, new components, PSPs provide an effective, reliable solution for repairing cracks, reestablishing wear areas in components, saving considerable time and money, and extending the life of engine components by up to 300%.
Unlike traditional brazing pastes and green tapes that require multiple re-brazing cycles and present the added problem of uncontrollable shrinkage, the porosity of MTC’s preforms is less than 2%, helping to eliminate shrinkage. Minimal post-braze grinding or machining is needed with PSP components.
About Morgan Technical Ceramics
Morgan Technical Ceramics manufactures components and sub-assemblies using an extensive range of materials, including structural and piezoelectric ceramics, dielectrics, braze alloys, and specialist coatings. It works with manufacturers’ design and R&D teams at local, national and international level on projects from concept and feasibility studies through prototype development to full production. The business employs some 2,500 people and has 23 manufacturing sites worldwide across Europe, the US, Mexico, China and Australia.
Morgan Technical Ceramics is a business within the Morgan Ceramics Division of The Morgan Crucible Company plc, one of the world’s leading advanced materials companies. The company specialises in the design, manufacture and marketing of ceramic and carbon products which are used in a wide range of applications, from transport and telecommunications to fire protection and medical instruments. Morgan Crucible is listed on the London Stock Exchange in the engineering sector.