The Morgan Advanced Materials Metals and Joining Centre of Excellence at Hayward, California focuses on research and development work for metallisation and brazing of metals and ceramic components. These components are essential in many critical operations in Aerospace, Medical and Semiconductor industries.
They have developed a novel technology to produce brittle brazing alloys in a flexible wire form. Due to the brittle nature of a number of braze alloys, they are traditionally supplied in paste, powder and melt spun foil forms. However, manufacture of a flexible wire form significantly improves the ability to apply these braze alloys in aerospace engine components, brazing heat exchanger systems, compressor components, structural engine components and many other applications. This novel product has been granted patents in the USA and Europe.
Morgan's New Bedford, Massachusetts site is a leader in the design and manufacture of implantable feedthroughs for the medical sector. These biocompatible components are used to bring signals from inside the human body to external connections. The CoE has developed a feedthrough where the density of connections surpasses the current state of the art for these products. This not only increases the miniaturisation of such devices, reducing the invasiveness of surgery, but also increases the number of signals that can be transmitted which can increase functionality of the implanted device. Our New Bedford facility is currently manufacturing the first prototypes for customer testing.
Our team has also developed a melt spun foil alloy based on the ternary titanium-cobalt-zirconium alloy family. This alloy facilitates a reduction in the temperature needed for brazing titanium metal in medical implantable devices to prevent grain growth and distortion and ensure a high integrity hermetic seal. Currently, we are using this alloy to assemble miniaturised medical devices.
With a drive for increasing fuel efficiency, the operating temperature of aero engines is steadily increasing. To meet the demands of increased temperature operation, we have developed a high temperature oxidation resistant feedthrough. These devices are used in the measurement of engine temperature during operation and the new braze alloy grades allow application from the current limit of around 950°F to over 1100°F. These feedthroughs are made in our New Bedford facility and are being introduced at two major engine sensor manufacturers.
Currently, our team is focusing on new materials and components for semiconductor and aerospace industries. In the semiconductor space, the team is developing new material solution for process chambers designed for next generation computer chips. In aerospace we are developing a high temperature braze alloy to join and repair engine parts. The growing team in the CoE is closely working with key customers in their R&D programs to bring new solutions to fruition in a timely manner and grow our business.