COMPANY PRESENTATION

More than a producer

COMPANY HISTORY 1916 to present...

Company history:Bolton Aerospace Ltd, formerly Delta (Manganese Bronze) Ltd / Cerro (Manganese Bronze) Ltd was established in London in 1876 as a producer of cast and wrought copper alloys. From then until the present day the factory has continued to produce high-quality brasses and bronzes in rod, bar, forgings, sections and hollows.

Timeline:1916 - The UK Government funded a factory to produce extruded copper-zinc products for munitions and the Manganese Bronze & Brass Co. Ltd accepted responsibility for overseeing production at Ipswich.1920 - The factory for wrought copper alloys was fully operational with rolling and extrusion facilities under the ownership of The Manganese Bronze & Brass Co.Ltd. It was one of the first company’s in the world to extrude aluminium bronze and other copper based alloys.1934 - The London based company, situated on the Thames, produced four of the largest propellers ever made for vessel #534, The Queen Mary.1938 - Extrusion and rolling of special alloys commence at Ipswich.

1962 - From the 1st of January, the company name was shortened to Manganese Bronze Ltd.1963 - The company was converted into a holding company called Manganese Bronze Holdings Ltd. Two subsidiaries were then subsequently established. Manganese Bronze Ltd to hold the wrought metals and a sintered materials division, both of which were based in Ipswich. 1969 - The sale of the Wrought Metal Division, group research laboratory and Sintered Materials Division was made to Delta Metal co. The company then traded under the name of Delta Manganese Bronze Ltd.1998 - Company purchased by The Marmon Group. An American privately owned business and traded under the name of Cerro Manganese Bronze Ltd.2007 - Company purchased by the Bolton Metals Group and re-named Bolton Manganese Bronze Ltd.2008 - Company name changed to Bolton Aerospace Ltd.

COMPANY HISTORY 1916 to present...

Produces specialist bronzes for niche markets Employs 132 personnel Location: The east of England in Ipswich Town, Suffolk. Capacity : 6 ktpa – Output : 3 ktpa

Plant and services 2000 tonne extrusion press capable of extruding from 0.394 inch up to 2.99 inch

bars. Two hot rolling mills capable of rolling 2 inch up to 7 inch diameter bars. Machine shop with CNC turning, milling and band saw capabilities. Foundry producing continuous, semi and static cast billet. X-RAY fluorescence analysis On-site chemical and mechanical testing laboratories

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Company Information

Aluminium Bronzes Special High Tensile Brasses & Bronzes Cast & Wrought Phosphor Bronzes and Gun Metals Special Alloys

• Cast and wrought products in the form of continuous castings, extruded, forged and hot-rolled products.

• A wide range of shapes and sizes-rounds, hexagons, squares, rectangles, discs, rings and hollows.

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Full Range of Copper Based Alloys

Aerospac

e, 50%

Automotive; 2%Fluid Power; 3%

Oil / Gas Field

, 10%

Ma-rine De-fenc

e; 20%

General En-gi-

neering; 15%

OUR MARKET SECTORS

Geographic Market Volume

NA,

60%

UK,

33%

ROW, 2% EUR, 5%

Virgin metalsAluminium, lead, tin, zinc ingotManganese flakeSilicon lumpsNickel cathode

  Purchased scrap

Soudronic copper Brass sheet cutsElectro-copper CoinageGranulated copper Cupro-nickelMonel Iron punchings

Process scrapBillet heads and tailsBar endsExtrusion discards/shellsSwarf

RAW MATERIALS USED IN MELTING

Controlled by x-ray fluorescence spectrometry.

The main spectrometer is a simultaneous instrument – analyses up to 20elements within 1 minute. Charge correction software can be utilised tocorrect melts to the correct chemistry.

We also have a sequential instrument as back-up. Slower analysis times, typically 5 to 7 minutes – but has the ability to analyse for a wider range of elements. 

CHEMICAL COMPOSITION

Generally used for brasses that are low volume and/or difficult to SCC cast.

Cast molten metal into cast iron or water cooled moulds.

Sizes – 150mm, 175mm, 225mm, 250mm and 325mm dia

Integrity of billet is lower than SCC or CC billet – more prone to porosity andinclusions.

Aluminium Bronze alloys are never static cast – turbulent mode of pouring would result in aluminium oxide inclusions.

STATIC CASTING

Ideal for large or small volumes. Flexible. Easy to change alloy, size and shape.

BA has 4 semi-continuous casting units. Cast sizes from 100 to 500mm dia

100, 150 and 200mm used for hot rolling stock

175 and 250mm used for extrusion billet

150 to 500mm used for forging stock

SEMI-CONTINUOUS CASTING

Ideal for large volumes of the same alloy, shape and size. High yield process.

Conticast100mm, 150mm, 175mm and 200mm dia billet in Aluminium Bronzes, Brasses or Special alloys

WertliRod and Bar - 12mm to 170mm diaHollow rod - 30mm to 160mm O/D, 10 to 30% wall thicknessMinimum batch size of 1 tonne.This machine is used for the production on AB tube and PB and GM rods.

CONTINUOUSLY CAST

BA has a 2000 tonne direct extrusion press. Billets are induction heated and then extruded into rod, bar or section.

Size rangesRounds 10 – 75mm DiaHexagon 12 – 70mm A/FSquare 16 – 90mm SqFlats 15mm x 10mm to 85mm x 20mm FL

Flats and squares have an extruded only tolerance of +2/-0mm

EXTRUSION

Small rolls 100mm dia stock 50mm to 70mm Standard rolls 150mm dia stock 75mm to 140mm Large rolls 200mm dia stock 145mm to

175mm BA rolls are 2 high reversing. Some alloys are rolled off-site – some special alloys or sizes

outside our range. The round rolled bars are hot straightened directly after the

rolling process.

HOT ROLLING

All forging work is carried out offsite by our approved sub-contractors

Hammer forging - round , square , rectangular , rings

Press forging - round , square , rectangular bar, rings

GFM forging - round bar, square bar, rectangular bar

Ring rolling

FORGING

Material can be heat treated on site or sub-contracted.

Stress relieving, annealing, water quenching and tempering.

Temperature ranges from 350 to 900 degrees celcius. 

HEAT TREATMENT

PACKAGING SOLUTIONS

WOODEN CASES

STEEL BOUND BUNDLES

POLY WRAPPED BUNDLES

Customer approvals include :

• Airbus SAS• Boeing DMS 2201

• Augusta Westland Helicopters• BAE Systems Military and Regional

• Hawker Beechcraft• Messier Dowty

• Rolls Royce RR9000 Sabre• Spirit Aero

Our quality management system is accredited by LRQA to:

ISO 9001:2008 AS 9100 Revision C 

Certificate number: LRQ 0902066

Process / service Dimensional checking - Tolerance

adherence Surface checking - Imperfections Mechanical Properties - Tensile, Impact –

Izod and Charpy Hardness - HB, HRB, HRC, HV Ultrasonic inspection - In house or UKAS Liquid penetrant inspection - In house or UKAS Metallography - Grain size, microstructure Electrical Conductivity - %IACS Magnetic Permeability

FINAL INSPECTION PROCESSES AND SERVICES

Test certification supplied to EN 10204:2004 3.1 as standard. 3.2 on request

Certificate of Conformity 

END OF PRESENTATION