Advanced Thinking in Advanced Materials NEWS RELEASE14.2 NEWS RELEASE Press Releases from April to...

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Press Releases fromApril to June 2014

Advanced Thinking in Advanced Materials

www.morganadvancedmaterials.com

Full speed ahead for Morgan and Bloodhound See page 2

Morgan offers new Diamonex® ClearShield™ wear-resistant window material ideal for high speed optical scanning See page 3

Morgan launches new Alphawool® Felt and Board range offering insulation up to 1600°C See page 7

Morgan expands capabilities for producing military components for Canadian and export markets See page 9

Full speed ahead for Morgan and Bloodhound

A British-led assault on the world land speed record has moved up a gear thanks to bespoke components from Morgan Advanced Materials. Working closely with the Bloodhound Supersonic Car (SSC) team, Morgan has been commissioned to design and manufacture custom parts to be used in various applications from ‘nose to tail’ drawing on the group’s broad range of engineering and materials expertise which ranges from composites to thermal management.

Led by Project Director Richard Noble and due to be driven by Andy Green, the Bloodhound world land speed record attempt is scheduled to take place in summer 2015 in South Africa with the twin aims of reaching speeds of 1,000mph (1,600kph approx) and motivating the next generation of British engineers to ‘confront and overcome the impossible using science, technology, engineering and mathematics’ (STEM).

Using racing car technology, the front half of the car takes the form of a carbon fibre monocoque – a rigid and secure ‘cell’ which provides optimum aerodynamics through its complex curvature as well as efficient air intake. The Morgan team will take responsibility for ballistic protection of the monocoque through designing, validating and manufacturing port and starboard panels which will shield the driver from any debris showers at high speed.

Morgan will also contribute to the lateral stability and aerodynamics of Bloodhound, working to provide an external surface covering for fin fairings on both sides as well as the leading edge of the fin itself. The fin has been designed to ensure stability throughout the

Mach range and is also likely to include antennae which form part of Bloodhound’s vital on-board communication infrastructure.

Finally, Morgan’s thermal management expertise will be utilised through a customised kit of fire protection parts and materials to be used across Bloodhound as well as the support equipment used in running the vehicle. In contrast to the carbon fibre compartment at the front of the vehicle, the rear of Bloodhound will comprise of a metallic framework and panels, with a combined length of 14m, adding an additional challenge for Morgan’s design, engineering and assembly teams.

Mark Robertshaw, CEO of Morgan Advanced Materials plc explained: “As well as a unique opportunity to help Bloodhound smash the world land speed record, our involvement in the project allows us to promote engineering as a career to young people in Britain. The opportunities in the field are varied, as Bloodhound proves, and our broad range of experience in creating custom solutions for the aerospace, defence and automotive sectors means we can give Bloodhound the best possible chance of securing supersonic speeds – and the record.”

Conor La Grue, Engineering Lead Commercial of Bloodhound SSC added: “Bringing together the expertise of specialist UK manufacturers, Bloodhound is a collaborative effort aimed at motivating the next generation of engineers. Breaking the record is the goal, but the true legacy of this iconic project will be in inspiring participation in STEM subjects, producing engineers ready to tackle the future challenges of industry.”

April 2014

Advanced Thinking in Advanced Materials 2

Image kindly supplied by Bloodhound SSC, taken by Stefan Marjoram

Morgan offers new Diamonex® ClearShield™ wear-resistant window material ideal for high speed optical scanning Morgan Advanced Materials announces the introduction of its new Diamonex® ClearShield™ scratch and wear-resistant window coating, developed to meet the electronics market’s rapid transition to optical image scanning and data capture. With an extremely clear appearance and exceptional hardness (more than 20 gigapascals), Diamonex® ClearShield™ has high optical transmission on glass and is optimized for imaging performance. It is ideal for high speed document and parts processing, optical comparators and inspection systems, travel and passport document readers, as well as security and other visioning systems.

Diamonex® ClearShield™ costs less than sapphire-laminated scanner glass products and the increased hardness of the Diamond Like Carbon coating makes it competitive for most applications.

Morgan has supplied superhard diamond-like carbon coatings, for use in retail point-of-sale scanners as well as medical device, military and aerospace applications for over 20 years Morgan has now expanded into products designed specifically for use in high performance digital imaging scanning equipment. The technology is for applications where broadband light

scatter can cause a loss in accuracy if the glass is not optically clear. Whether for accurate optical transmission for inventory parts management, high speed document scanning, blueprint reproduction, or scanning of financial documents, Diamonex® ClearShield™ offers a clear, scratch resistant coating that provides years of wear resistance even in the toughest environments.

April 2014

Morgan announces availability of Superwool® fibre papers for expansion joints, back-up insulation, and gasketsMorgan Advanced Materials announces the availability of Superwool® fibre papers, a low bio-persistent solution ideal for use in ceramics, glass and metals manufacturing processes, as well as in commercial automotive and consumer goods applications. Offering a low bio-persistent-solution, the papers are non-wetting to molten aluminum and feature low thermal conductivity, excellent tensile strength, thermal stability, and resistance to chemical attack. Their wide variety of uses includes expansion joints, back-up insulation, gasket applications, and heat shields for kilns, home appliances, and even air bags. The papers facilitate energy conservation, and can also be used to develop economic lining solutions.

Uniquely designed from Superwool bulk and organic binders, Superwool papers are specially processed to offer excellent performance in high-temperature applications and feature a classification temperature of up to 2372°F.

Flexible and tear-resistant Superwool papers are widely used for expansion joints in trough sections, furnace tap-out plug cover and parting agents, and as a back-up insulation layer behind refractory materials for melting and holding furnaces. The range of papers includes Superwool 351-E and Superwool 406-E, intumescent papers that expand up to 400 percent making them a good choice for gasket and fire protection applications.

All Superwool papers can be customized to specific application requirements by hand, water jet, or CNC machining.

Morgan Advanced Materials papers are manufactured in the Augusta, Georgia facility under ISO9001:2008 requirements. Many of the papers meet strict automotive, aerospace andindustrial specifications, and customers will be able to identify the ideal application insulation solution from this extensive product offering.

May 2014

www.morganadvancedmaterials.com 3

Morgan launches new Alphawool® Felt and Board range offering insulation up to 1600°CThe Thermal Ceramics business of Morgan Advanced Materials, a world-leading manufacturer of highly engineered insulating materials, has further expanded its high-performance industrial insulation range with the addition of felt and board products made from its newly developed Alphawool® polycrystalline insulation wool for applications in the iron and steel, ceramics, petrochemical and other sectors.

Suitable for expansion joints, furnace lining and gaskets, Alphawool® Unifelt and Alphawool® VF board are manufactured at Morgan’s specialist facility in Lillebonne, France.

Alphawool® VF board is a high-temperature board vacuum formed from Alphawool bulk fibres, offering dimensional resilience and excellent resistance to thermal shock. With low thermal conductivity and low shrinkage up to the classification temperature of 1600ºC, the boards come in thicknesses from 10mm to 50mm (sanded or unsanded) and can be pre-fired if required.

With a classification temperature of 1600°C, Alphawool Unifelt combines flexibility, light weight, high heat resistance and low thermal conductivity and comes in a variety of thicknesses from 6mm to 50mm.

Boasting high chemical purity and excellent thermal and chemical stability in industrial process conditions, both products are quick and simple to cut and offer low heat storage alongside excellent insulating performance.

Alphawool is unclassified under the European CLP regulation (Directive 1272/2008) by virtue of its very low content of respirable fibres. This is a key advantage given the strict regulation of chemicals under the European REACH regulation.Further research and development into new products harnessing the capabilities of Alphawool fibres is currently ongoing.

Dave Barrington of Morgan Advanced Materials commented: “Achieving optimum insulation is key to reducing process cycle times and energy costs, especially at higher temperatures, and compliance with local and international safety regulations is equally important. Alphawool Unifelt and Alphawool VF board deliver on both counts – drawing on Morgan’s extensive experience in thermal engineering to produce optimum performance, longevity and ease of use.”

May 2014


Offering highly reliable detection of air bubbles in medical dosing applications, the acclaimed range of air-in-line (AIL) sensors from Morgan Advanced Materials has been extended to provide two new capabilities in line with demand from medical original equipment manufacturers (OEMs).

Developed in response to customers’ need to optimise infusion lines and liquid dispensing equipment, the first of two new products enables increased control over the detection of air bubbles in liquids which, if undetected, could hamper the functioning of drug delivery systems or allow bubbles to enter the patient’s bloodstream – a potentially fatal consequence. Enhanced AIL sensors allow the detection of the size of air bubbles in tubes, meaning sensors can be easily configured for different applications.

Already offering AIL sensors for 6.35mm and 4mm tubing, the second new addition to Morgan’s range is a sensor specifically designed for 2.5mm diameter tubing. Allowing detection of air bubbles in much narrower tubes, the new sensor is ideal for use in compact medical equipment where space inside may be limited.

Oliver Ridd of Morgan Advanced Materials commented: “Morgan’s ultrasonic AIL sensors are used in a wide range of medical equipment such as haemodialysis machines, cardio-pulmonary by

pass systems and infusion pumps. They help prevent air bubbles from entering a patient’s bloodstream which could have potentially fatal consequences. With our dedicated design and development team we are continually expanding and improving the capabilities of our sensors. Our speciality lies in designing bespoke products dependant on customer requirements and these two new capabilities serve to broaden the already extensive range of applications for AIL sensors and further increase the scope for customised solutions.”

Morgan extends air-in-line sensor capabilitiesMay 2014

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Morgan launches lightweight soldier protection systemMay 2014

Morgan Advanced Materials announces the launch of its latest innovation in soldier protection, the Lightweight Armour Solider Architecture (LASA) system, designed to give the wearer maximum protection whilst simultaneously providing freedom of movement with its lightweight structure.

The LASA protection system offers bespoke, integrated load carriage and head sub-systems to fulfil mission-critical protection. It includes fully compatible head, torso and lower body armour which offer comprehensive protection for soldiers in combat.

Morgan’s Composites and Defence Systems business, a leading supplier of lightweight combat-proven body armour products to the global defence sector, has challenged the traditional basic equation for body armour, whereby the higher the threat, the heavier the plate. New materials and technologies have allowed Morgan to develop the most advanced armour soldier system in the world, providing the wearer with a 25% weight reduction compared with rival systems, without compromise on protection. Thanks to the significant load reduction, the LASA system also improves mobility and reduces wearer fatigue.

The head protection of the LASA system provides a weight saving of approximately 30% over current in-service products. The helmets are fitted with a four-point chin strap, maximising stability and operational security during impact scenarios. The innovative bracket system accommodates multiple accessories including visors, mandible guards and night vision goggles without the need for additional drilling of the shell.

Providing significant enhancement in security and comfort over current in-service solutions, the torso system is fully compatible with the family of helmets and lower body protection, delivering maximum coverage and protection while maintaining optimum comfort, whilst also ensuring that the soldier can fire from any position including prone. The body armour is ultra-lightweight

and durable, specifically designed for the rugged environments encountered by international military and security personnel. The lower body system is designed to maintain product shape for longer, enhancing field performance and reducing life cycle costs. Other equipment includes pelvic protection, which is secure and comfortable while patrolling on foot or by vehicle, and knee pads which are designed to be fully operable in rough terrain.

Duncan Eldridge, President of Morgan Composites and Defence Systems, said: “We have conducted significant research and development to test the boundaries of what is possible with soldier protection systems. While safety remains paramount, reducing weight is key to enhancing mobility and minimising fatigue. The engineering team has been working on developments to provide a 30% weight saving on our world leading helmets and a 25% weight saving on Ballistic Plates compared with competitive solutions.

“Morgan has a skilled team of qualified engineers specifically tasked with developing armour and soldier systems. Our in-house testing facilities include, helmet impact testing rigs for validation and development, instrumented and calibrated gas guns for fragment simulating projectile testing, and an independent UKAS 17025 accredited ballistics range, allowing rapid turnaround for iterative design and development activities.

“We have unparalleled experience in the development and manufacture of new systems to meet specific and urgent customer requirements. With these onsite facilities we are able to rapidly prototype and test various design iterations for urgent system development and deployment requirements.”

In conjunction with the launch of the new system, Morgan has developed an interactive soldier which will be available to view on the company’s website. The 3D interactive model allows users to see the variety of soldier protection systems available, and provides detailed descriptions on the

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Morgan’s advanced alumina ceramic finds niche in oncology equipment

Thanks to its excellent dielectric properties and a reliable surface finish, a high-quality alumina ceramic from Morgan Advanced Materials is now being successfully used in radiotherapy equipment for oncology treatment.

Deranox™ 970 is a high-density, non-porous and vacuum-tight material with a 97 per cent Al2O3 (aluminium oxide) content which provides excellent electrical insulation. It is frequently used in high-vacuum systems, in laser and microscope applications and as an insulator in medical and scientific equipment, and has now beenspecified as the sealing element for RF windows in radiotherapy equipment. Acting as a mechanical seal at either end of the vacuum chamber through which electron beams pass in the radiotherapy process, RF windows maintain the integrity of the vacuum, allowing electrons to pass through while preventing both ingress of contaminants and vacuum leakage.

Yannick Galais from Morgan explains: “While most solutions for RF windows contain around 97 per cent alumina, it is the remaining 3 per cent that makes all the difference in dielectric performance. The alumina ceramic formulation of Deranox™ 970 provides a high dielectric constant – 9.85 and 9.84 at 2.8GHz and 2.9GHz respectively - and low loss tangent – 0.00109 and 0.00110 at 2.8GHz and 2.9GHz respectively. Externally tested and verified by an independent and fully accredited testing house to an internationally recognised standard, ASTM D2520, these properties contribute to excellent stability at high frequencies.

“Our sophisticated powder manufacturing processes provide excellent repeatability from batch to batch, between batches, which is a key parameter in tuning the nominal wavelength and beam frequency which will ultimately determine the performance of the of the radiotherapy machine. Our precision machining capabilities guarantee a consistent surface finish and flatness preventing RF reflectance and thus eliminating heat and leakage over time. Providing an impurity-free surface finish also improves the performance of the radiotherapy machinery by removing any potential for oxidation on the RF window.”

Using advanced simulation techniques and extensive modelling, Deranox™ 970 has been comprehensively tested for radiotherapy

applications prior to the prototype stage to ensure its suitability – followed by in-depth real-life testing to ensure optimum performance within a very tight tolerance range. Developed alongside Deranox™ 970 for radiotherapy equipment, Morgan has also introduced a tailored moly-manganese metallising ink to facilitate the bonding process when the RF window is brazed to the body of the machine, creating the optimum seal and safeguarding the vacuum. As each RF window is individually designed for specific machinery, Morgan’s inks are custom formulated for each material grade. In addition to the ceramic, Morgan is able to supply the complete RF window sub-assembly including mounting flanges. Innovative design features allow Morgan to offer ceramic RF windows brazed inside the oxygen free copper (OFC) vacuum chamber.

Mr Galais continues: “RF windows made of Deranox™ 970 will last the lifetime of the radiotherapy equipment – generally 20 years plus. Within the highly time-sensitive oncology treatment pathway, disruption to therapy machinery is simply not an option and failure of an RF window will often require full replacement of the radiotherapy machine, at enormous cost to the hospital trust and causing unacceptable delays for patients. The purity of our Deranox™ 970 material, coupled with its reliable dielectric properties and Morgan’s extensive modelling and test processes, ensure a high-quality RF window solution with long-lasting performance.”

Morgan supplies a range of other components for radiotherapy and diagnosis equipment including high-voltage capacitors and feedthroughs. In radiology, Morgan’s ceramic to metal cathode insulators can be used as image amplifiers in CT and PET equipment, providing exceptional performance in a deep vacuum environment. Similarly, in MRI systems, brazed assemblies produced by Morgan are frequently used in high voltage, high power applications in conjunction with super conductivity coils.

Morgan also produces cutting edge oncology therapy couches. Providing optimised structural design using precise fibre orientation in lay-up, the couch uses advanced composites rather than metal components to help ensure that patients are positioned correctly for optimum treatment, enabling higher image quality and lower radiation doses.

May 2014

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Morgan Advanced Materials announces the availability of its Certech injection-molded ceramics, specifically engineered for investment casting of airfoils and industrial gas turbines (IGTs). Morgan manufactures cores in a wide range of sizes and complex designs for equiax, single crystal, and directional solidification (DS) casting.

Critical airfoils required to withstand the high turbine inlet temperature in modern gas turbine engines are investment cast in nickel and cobalt-based superalloys, with ceramic cores used to form the part’s air-cooling passages. Morgan’s ability to inject around quartz rods down to 0.020-inch (0.5 mm) in diameter has provided customers with the freedom to design features in the cooling passages that would otherwise be difficult to form.

Morgan has also invested in both its capacity and technology to support the increased production of industrial gas turbine generators to meet growing global power demand. The unique process offers short lead-time and meets high volume production requirements. Cores can be supplied in a fully “wax prepared” condition, hollow for more uniform section of product, or with quartz for local strengthening and the formation of small exit features. Further, technical engineers work closely with customers from design through prototyping and production for the aerospace and power generation industries, offering AS9100 quality and full traceability.The company’s unique offering includes ceramic cores produced using

its specialty P-52 and newly developed P-57 and P-59 materials which now allow the production of cores with extremely thin (<0.012”) dimensions without sacrificing stability. These “next generation cores” can be chemically dissolved after the casting has cooled, leaving the clean air passage replica needed in today’s efficient turbine engines.

While dimensionally stable at high temperatures, these core materials also exhibit improved crushability during solidification. They remain rigid and stable through the casting process, but are crushable when required during the metal solidification process. This is particularly important for alloys that are prone to hot-tearing (in equiax castings and directionally solidified castings) and/or recrystallization (single crystal castings)


Morgan offers advanced injection-molded ceramics for investment casting of airfoils and industrial gas turbine cores

May 2014

Morgan launches new Alphawool® insulating Bulk Fibre providing insulation up to 1600°C for the vacuum forming sector A new brand of polycrystalline insulation wool designed specifically for the vacuum forming market is now exclusively available from Morgan Advanced Materials. The new Alphawool® bulk long-fibre product is manufactured at a dedicated facility in the UK.

Two grades are available – Alphawool® LA with a classification temperature of 1500ºC and Alphawool® HA which has a classification temperature of 1600ºC. It does not contain a binder and so emits no fumes or smell during first use. A high alumina content of between 96 and 97 per cent, with low ‘shot’ content below one per cent, creates a lightweight yet highly resilient product which is chemically and thermally stable, with low linear shrinkage, low thermal mass and strong insulating properties.

Alphawool is unclassified under the European CLP regulation (Directive 1272/2008) by virtue of its very low content of respirable fibres.

Alphawool bulk is suitable for the production of all types of boards, shapes and textiles for a diverse range of applications in sectors from glass production and petrochemical to electrical kilns and laboratory equipment.

Dave Barrington of Morgan Advanced Materials commented: “The creation of our own dedicated facility to manufacture Alphawool fibres reflects our commitment to the sector and provides a guarantee to customers of quality and availability.

“Backed by Morgan’s technical innovation and unrivalled customer support, we are confident that Alphawool bulk will become the material of choice for the world vacuum forming sector.”

June 2014

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June 2014

Investment in special purpose CNC cylindrical coating equipment has further increased Morgan’s refractory metallisation coating capacity at its Rugby site in the UK.

The new equipment will increase the manufacturing capacity while improving uniformity and repeatability of coating thickness from part to part and batch to batch. It provides the flexibility needed to produce both small and large volumes, ideal for prototyping through to full scale production. It also enhances the coating band positional and dimensional tolerance capability of Morgan’s metallised ceramic products used in metal to ceramic feed-throughs and brazed assemblies. Crucial for hermeticity, bond strength and reliability in service, metallisation inks from Morgan stand up to even the harshest operating environments demanded by industrial processes, including industial igniters and seal or pin-base assemblies.

Phil Shakespeare, Engineering Manager at Morgan Advanced Materials, explained: “The ability to apply our existing range of inks was key to the success of the new machine. Working closely with our equipment manufacturer, we have been able to develop an automated machine to apply thick film / refractory metallising inks to cylindrical surfaces which is fully calibrated with our existing formulations. Importantly, that means

there is no change to the microstructure of the metallisation layers we have routinely supplied to our customers for their metallised ceramic components, feedthroughs and assemblies.

“The machine complements traditional hand-coating methods which will still be used where necessary, for example where customers’ validation is based upon hand application. We are to work closely with customers to improve the performance and reliability of their components, allowing them to optimise their assembly processes, improve yields and reduce their overall manufacturing cost.”

Morgan offers a proven range of metallising inks, designed to work with specific grades in its range of ceramic materials to provide optimum bond strength. The company also produces its own braze alloys to offer a fully integrated capability.

Morgan also manufactures complete feed-throughs and metal to ceramic brazed assemblies. The new investment enables Morgan to continue its growth in the supply of these products with improved process capability, which when combined with design expertise in high performance metal to ceramic feedthroughs and assemblies, benefits customers with ‘designed for manufacture’ solutions.

Morgan investment boosts ceramic metallising capability

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New feedthroughs with increased power and pressure performanceMorgan Advanced Materials (Morgan) has launched a new service providing high-voltage ceramic-to-metal feedthroughs capable of performing with voltages in excess of 100kV DC while also withstanding pressures of up to 1,700 bar (25,000 psi).The launch is in response to increased demand for higher-specification products from sectors including oil and gas, nuclear energy and medical diagnostics

Based around Morgan’s acclaimed Deranox 970 high dielectric strength ceramic, each product is designed and manufactured in line with specific customer requirements.

Yannick Galais of Morgan explained: “Ceramic feedthroughs have become widely established as the product of choice for high-voltage applications as other materials can struggle to cope from an electrical or mechanical point of view. We have seen a trend towards applications with highly tailored and extremely demanding requirements, meaning standard products are not always suitable in terms of their design and specification. Failure of these products cannot be tolerated as the ‘corona’ effect caused by undesired voltage build-up can result in catastrophic failure of an entire system and costly, unscheduled downtime.

“Drawing on their experience in the design of ceramic-to-metal

brazed assemblies, our team of engineers work with customers from the outset to develop a fully integrated, optimised solution based on our proven range of ceramic materials, metallisation inks, high-temperature glazes and braze alloys. Materials are carefully selected and integrated into a design which will minimise the impact of the ‘corona’ effect and deliver reliable long-term performance in the most demanding conditions.”

Applications for high-voltage feedthroughs range from powering electric pumps used on the seabed in oil and gas exploration, to neutron generators for non-destructive testing applications in the nuclear power generation sector. Another primary user is the medical sector, for anode and cathode connectors in x-ray, scanning and diagnostic equipment.

June 2014

Morgan Advanced Materials announces that it has relocated its Composites and Defence Systems business to Burlington, Ontario, which is an existing Morgan manufacturing site. Relocating to this site will offer increased capabilities for advanced composite hard armor, soldier systems, vehicle armor, lightweight vehicle technology, and aerospace armor.

Combining technical expertise and equipment from three different plants located throughout Canada, the new Burlington site now offers a highly skilled workforce of more than 50, as well as 100,000 square feet of manufacturing space, which is five times more the capacity than the prior manufacturing facilities.

The transition allows Morgan to refocus its resources to be more engineering based, providing customized composite systems for defense applications used in the world’s most advanced lightweight armor solutions. The transition is expected to help Morgan produce highly advanced components in Canada for the Canadian market and for export.

“The increased headcount, new space and new equipment at the Burlington site give us a great capacity boost that will allow us to supply our customers with the latest products for protection of soldiers in the military,” said Duncan Eldridge, President of Morgan Composites and Defence Systems.

Morgan expands Burlington, Ontario capabilities for producing military components for Canadian and export markets

June 2014

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Morgan Advanced Materials, a global leader in high-specification piezo ceramic (PZT) components for defence and commercial sonar applications, has announced a further expansion in its capabilities in this sector.

The company’s facility at Southampton, UK, is now able to manufacture fully encapsulated hydrophone assemblies.

Morgan is an established manufacturer of PZT plates, discs, tubes and (omnidirectional) spherical hydrophones. These are used in both active and passive sonar applications to aid navigation and article / diver detection by providing detailed one-, two- or three-dimensional information on the size, position, distance and movements of objects beneath the surface of the ocean.

The company’s dedicated team of application engineers is able to recommend the most appropriate PZT formulation from an extensive range and then fine-tune it to the customer’s specific application requirements. Morgan can supply everything from the base piezo ceramic material, to complete and fully encapsulated hydrophone units. Morgan is able to design and manufacture custom hydrophones and

uses the latest underwater facilities to test the performance of hydrophones both at prototype and production stages.

Accuracy and performance can be optimised on (planar) tube hydrophones as a specific example by using the company’s enhanced striping capabilities which ensure the creation of regular, repeatable patterns on the inside surfaces of PZT tubes. These can be pre-stressed before supply for increased performance should that be required.Dr. Peter Thomas at Morgan explained: As an established supplier into the sector, we have a detailed understanding of the performance requirements for hydrophone products. Many of the OEMs and Tier 1 and Tier 2 suppliers are keen to reduce the size of their supply chains, so being able to provide complete hydrophones, combining state-of-the-art materials, design, underwater testing facilities and manufacturing, positions us ideally to maintain and develop our business in this sector.

“With our extensive knowledge of hydrophones and access to an extensive range of high-performance materials, we are able to design and deliver a cost-effective solution for virtually any application.”

New capability enhances Morgan’s SONAR offeringJune 2014

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Morgan develops innovative ceramic to ceramic bonding technique

An innovative and powerful ceramic to ceramic bonding technique has been developed by Morgan specifically for use in demanding high-pressure fluid handling and vacuum applications.

Using a preparatory formulation applied to one or both faces of the parts to be joined, the bonding technique delivers high tensile strength. The process is suitable for bonding both porous and fully dense ceramics, making it ideal for a variety of applications from fluid handling systems to diode pump lasers.

Internal testing of the new bonding technology has delivered impressive results, with a bond strength of 132 MPa and a force to failure of 11,330kgf. Both of these figures represent a level of performance many times that of co-firing (7.7 MPa and 577.97 kgf in the same application) and adhesive bonding (5.4 MPA and 460.33 kgf). This data is summarised in the table below.

Description of bonding

method

Leak Test of the bond (mbar l / s)

Force to Failure

(kgf) of the Bond

Strength of Bond (MPa)

Mode of Faiure

Bonding by Co-firing

- 577.97 6.7 Came apart at the bond

Bonded using an adhesive

10-8 460.33 5.4 Came apart at the bond

Bonded using

Morgan proprietary

bonding technology

10-8 11330.00 132

For all assemblies, the bond

stayed intact

Note: Tested in a controlled and a systematic manner to an in-house method and not any international standards

This table shows that the bonding technology is also leak-tight to 10-8 mbar l/s.

Yannick Galais of Morgan explained: “The ability to deliver a high-strength bond has many benefits for customers. It results in a faster process than metallising and brazing and does not require multiple high temperature processing steps. Morgan’s bonding technique is also highly cost-effective. In-house testing has shown that the technique produces bonds which are just as strong as braze or metallised assemblies. This innovative bonding technology is also suitable for assemblies with complex joints, providing a strong bond even on applications with complicated geometry.”

Ideally suited to pressurised applications, the technique can be used in fluid handling assemblies requiring leak-tight joints. It can also provide a hermetic joint with vacuum levels down to 10-8 mbar where electrical insulation or containment is required.

Internal pressure tests have shown that the joint can withstand pressures in excess of 25 bar (design dependant). Tightly controlled tolerances and clearances allow Morgan’s engineers to design systems in which a captivated rotor using this bonding technology can operate in a high-pressure environment. Such design features and technology open new opportunities for applications where pressure differential principles are applied, such as desalination.

In other applications such as high power diode pump lasers (DPSS), the bonding technology offers the possibility to design hybrid components, for example, combining reflective porous ceramic with a dense ceramic material. In such a hybrid construction, high-reflectivity Sintox AL is bounded to Deranox 995. Sintox AL provides a good ‘scatter’ of the laser light thanks to its particle size which gives the material excellent microstructural control of defined porosity. The material provides a highly diffuse reflectance, behaving as a bulk reflector of the source of radiation by both reflecting and refracting light back into the cavity. Deranox 995 provides high strength and impervious properties for the cooling fluid. The high mechanical strength of the Deranox 995 provides the structural rigidity needed to mount the diode stack and at the same time machined cooling channels in the dense material allow the cooling media to operate without any contact with the diode stacks.

June 2014

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For all enquiries, please contact our specialist sales and manufacturing sites:

Europe Morgan Advanced Materials Morgan Drive Stourport-on-Severn Worcestershire DY13 8DW United Kingdom

T +44 (0) 1299 872210 F +44 (0) 1299 872218 [email protected]

AsiaMorgan Advanced Materials 150 Kampong Ampat 05-06A KA Centre Singapore 368324

T +65 6595 0000 F +65 6595 0005 [email protected]

South AmericaMorgan Advanced Materials Avenida do Taboão 3265- São Bernardo do Campo – SP CEP 09656 000 Brasil


North AmericaMorgan Advanced Materials 4000 Westchase BoulevardSuite 170, Raleigh, NC 27607-3970USA


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Windsor, Berkshire, SL4 1LP United Kingdom

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