14.3

NEW

S RE

LEAS

E

Press Releases fromJuly to September 2014

Advanced Thinking in Advanced Materials

www.morganadvancedmaterials.com

The University of Manchester partners with Morgan Advanced Materials for graphene development See page 9

Morgan leads the way in production of large dimension PZT Blocks See page 2

Morgan Advanced Material’s royal visitor at Royal International Air Tattoo See page 5

Morgan and Bloodhound gearing up for land speed record attempt See page 10

Morgan Advanced Materials provides extended Electrostatic Chuck life through replaceable, wear-resistant films Morgan Advanced Materials announces new solutions in sacrificial wear layers to extend the life of alumina or beryllia electrostatic chucks (ESCs) for semiconductor, solar and LED applications. Applied as a final protective layer, the Diamonex® technical hard-coats offer extended life benefits to new or refurbished ESCs.

These thin, wear-resistant films, made of diamond-like-carbon (DLC) and other nanocomposite materials, are adjusted to meet specific resistivity requirements of the ESC while protecting electronic layers and extending the overall life of the part. They have a broad range of chemical resistance, meet chamber process compatibility requirements, and can withstand high-temperature heated chuck applications.

The hard-coats can be applied to new or refurbished ESCs, even for ESCs originally designed without a sacrificial wear layer. The technical films are available for CVD, PVD, etch and ion implant processes. The films feature mesa patterning for low defectivity and can be used in most high temperature processes.

July 2014

Morgan Advanced Materials leads the way in production of large dimension PZT Blocks

In a major breakthrough for the technical ceramics industry, Morgan Advanced Materials is manufacturing what are believed to be the world’s thickest piezoelectric ceramic blocks.

The blocks, designed for use in ultra-low frequency SONAR applications down to 18KHz, are made of high-quality, soft (Navy II) lead zirconate titanate - Morgan’s own proprietary formulation, known as PZT5A1. The blocks offer superb electrical characteristics, are of high sintered density and come in a choice of nine, highly sensitive ‘soft’ PZT formulations. They are suitable for the manufacture of wide bandwidth 1-3 composite transducers.

However, the most striking feature of Morgan’s new PZT ceramic blocks is their size, and in particular their thickness, reaching a current maximum of 48mm. Various combinations of length and width are available on request. The ability to manufacture and polarise such large thicknesses of piezoelectric materials sets Morgan apart from its competitors and represents a step change in the industry.

“Our philosophy is to push the boundaries in the manufacture of large piezoelectric components and to support the next generation of ultra-low frequency, high resolution SONAR equipment. I do not know of any other company that is producing piezoelectric components to such demanding thickness specifications,” commented Frédéric Pimparel, Technical Manager - Piezoelectric Components at Morgan Advanced Materials.

Large dimension PZT blocks are suited to a range of high-integrity applications, such as side scan SONAR, sub bottom profilers and transducers for surveying systems. The ‘soft’ PZT from which they are made provides excellent sensitivity and permittivity, which makes it ideal for use in sensing applications requiring a wide bandwidth. Thanks to the cutting-edge pressing and firing techniques employed during manufacture, Morgan’s large PZT block boasts a uniform consistency of electro-mechanical properties throughout each component, and can be ground and lapped to precise limits. The large PZT block is available in block form or as diced and filled with specially formulated epoxies for use in 1-3 composites, with a range of metallisation treatments also available.

July 2014

Morgan announces advances in their range of high purity materials for semiconductor applicationsMorgan Advanced Materials announces advances in their range of materials grown using chemical vapor deposition (CVD) processes. Morgan’s CVD Silicon Carbide (SiC) and Pyrolytic Boron Nitride (PBN) materials are ideal for use in semiconductor applications, including rapid thermal processing and plasma etch process chamber components, as well as metalorganic CVD tools for high-brightness white LED manufacturing using the indium gallium nitride process.

Morgan’s improved CVD SiC growth capability enables the manufacture of 300+ millimeter diameter components with thicknesses of more than 10mm at production volumes for recently developed plasma etch applications. With access to world class ultrasonic machining capability, Morgan offers high tolerance CNC machining and precision hard grinding, as well as the patented Rmax process for producing focus CVD SiC ring shapes.

Morgan’s high purity (99.999 percent+) SiC material has high thermal conductivity, is resistant to chemical erosion, and features minimal particulate generation, making it ideal for use in chlorine and fluorine plasma etch processes. The material is ideally suited for use in producing GDMs (gas distribution plates) where the material’s erosion resistance can lead to long life and extended tool PM schedules. Ultrasonic drilling can provide holes with diameters as small as 0.5mm, ideal for custom etch applications.

High purity (99.99 percent+) PBN materials have a working temperature in excess of 1500°C, and feature high electrical resistivity and high dielectric strength. Extremely low out-gassing, non-wetting, and non-toxic, the PBN materials are inert to most acids, alkalis and organic solvents and have high thermal conductivity in the “a” direction. The advanced materials are a good choice for manufacturers of PBN coated graphite heaters and PBN effusion cell components.

July 2014

Advanced Thinking in Advanced Materials www.morganadvancedmaterials.com2 3

Advanced Thinking in Advanced Materials www.morganadvancedmaterials.com4 5

This year’s Royal International Air Tattoo certainly lived up to its name for Morgan Advanced Materials, with the company welcoming HRH The Prince of Wales to its stand at the event. The Prince showed great interest in exhibits such as the company’s latest EOD (explosive ordnance disposal) suits and body armour plates.

Morgan used the event to enthuse younger visitors about the prospects of careers in science and engineering having been invited to attend by the Royal Air Force Charitable Trust. The company’s ‘Ambassadors’ – made up of recent graduate recruits and experienced engineers – were on hand to highlight the multiple career paths open to pupils choosing to study STEM (science, technology, engineering and maths) subjects.

Luca Leone of Morgan commented: “Our presence at the show – the first time we have exhibited there - was a great success and we were overwhelmed by the interest in our exhibits from visitors of all ages who took the opportunity to see at first hand the Mastiff armoured vehicle, which has saved so many lives in Afghanistan.

“Many of them also donned the uniform used by bomb disposal experts and handled the armour plates supplied by Morgan to our armed forces – both applications where we have delivered significant weight reductions in recent years, improving mobility and reducing fatigue for the user.

“The Prince was clearly enthused by what he saw, as were many of the younger visitors who left with renewed enthusiasm for science and engineering.”

Morgan’s new MAT-240 material keeps pumps running in extreme environments

Formulated specifically for dry or vacuum conditions, the new MAT-240 material developed by Morgan Advanced Materials is helping to keep pumps and seals running in challenging operating environments.

Morgan’s MAT-240 material is ideal for extreme conditions which are intolerable to other carbon graphite materials, due to the special formulation which allows for self-lubricating.

MAT-240 transfers a lubricous film which withstands dry conditions, steam and vacuum applications, and a range of operating environments including marginally and fully lubricated. Prior to launch, MAT-240 was successfully trialled in mixer seals which featured a dry nitrogen barrier. Here, no other carbon or graphite material was able to provide protection without the presence of polar gases.

Additionally, the new material has proved its suitability in methane gas, steam and air applications, including the most demanding dry applications across a temperature range of cryogenic to around 230°C. Its performance at high and low temperatures makes it ideal for use in food processing applications where

extremes of temperature are used for cooking and freezing, and MAT-240 has been recognised as safe for food handling operations by the US Food & Drug Administration (FDA).

Michael Ritter of Morgan Advanced Materials explains: “Extensive internal testing has shown that the coefficient of friction of MAT-240 is less than half that of other comparable materials, meaning it offers significantly improved wear resistance.

“Additionally, when running in dry nitrogen, MAT-240’s friction values are again proven to be less than half the values of typical carbon and graphite materials. These properties help keep pumps and seals running for longer than has previously been possible in dry and other challenging operating conditions, maximising uptime and reducing replacement costs.”

July 2014

Morgan Advanced Material’s royal visitor at Royal International Air Tattoo

July 2014

Advanced Thinking in Advanced Materials www.morganadvancedmaterials.com6 7

Morgan Advanced Materials’s Composites and Defence Systems business offers customized military armored composite crew compartmentsMorgan Advanced Materials (Morgan) announces that survivability solutions offered by its Composites and Defence systems business are being used in customized armored composite crew compartments, ideal for reconnaissance and tactical vehicles, as well as Special Forces vehicles.

Morgan’s crew protection expertise is based upon its composite and ceramic pod technology, which has been developed over the past 20 years. The pod creates a detachable, blast and ballistic-resistant crew compartment, which can be easily integrated into customer-produced chassis and can be modified to provide higher levels of protection if required.

Morgan recently drew on its extensive materials and engineering expertise to design and develop a custom composite crew compartment for Tata Motors’ Light Armored Multipurpose Vehicle (LAMV) program for the Indian Ministry of Defense. The composite and ceramic pod provides a weight saving of more than 1000 kilograms (2204 pounds), making it less than half the weight of a similarly protected steel structure.

According to Duncan Eldridge, President of Morgan Composites & Defense Systems, “Morgan is a world-leading designer of armored systems for military vehicles, with unrivalled experience in both ceramics and composites, enabling it to deliver crew protection with optimum performance at the lowest possible weight.

Our success with the Indian Ministry of Defense’s LAMV program is just the latest of example of how we can develop armor system as part of a strategic relationship that opens up opportunities for both companies.”

July 2014

Morgan Advanced Materials extends Reflector Glaze Range

July 2014

Developed for high-energy pulsed Q-switching infrared laser applications, a new, high-absorption samarium oxide glaze from Morgan Advanced Materials means it is now able to offer three grades of glaze for laser systems. The samarium glaze absorbs radiation at the Nd-YAG lasing wavelength of 1,064nm, and its further transitions near 940nm, 1120nm, 1320nm and 1440nm. A significant amount of fluorescent radiation at the lasing wavelength escapes laterally from the laser rod into the surrounding pumping cavity.

Absorbing this radiation prevents it from being reflected back into the laser rod, which would in turn stimulate decay from the upper laser transition level, thereby limiting the number of excited ions which can occupy that level. By preventing this decay, the maximum output energy obtained from the laser is increased. Morgan’s high- absorption samarium oxide glaze is formulated through the controlled addition of dopant to create optimum reflectance properties

Applying the glaze to Morgan’s Sintox AL laser pump cavity material produces the high diffuse reflectivity required to achieve uniform illumination of the laser rod surface. Providing typically 98 per cent reflectance in the desired wavelength range, the new samarium oxide glaze matches yellow (GSY) and clear (GSO)

glazes between 700 nm and 900nm. The optimum reflectance capability across the range of three glazes now spans wavelengths of around 580nm up to 2,000nm.

Tony Beswick of from Morgan explains: “As diode laser technology becomes more specialised, we continually evaluate our glaze formulations, in partnership with leading laser manufacturers, to improve the reliability of new equipment. Our samarium oxide glaze improves performance in the specified wavelength range and is suitable for high-energy, niche applications such as industrial metal cutting. “The new glaze perfectly complements our existing yellow glaze - which reduces laser cavity temperatures by absorbing extremely low wavelengths, meaning less cooling fluid needs to be used – as well as our clear glaze, which seals ceramic reflectors against the ingress of cooling fluid.”

Morgan’s laser reflectors are produced from high-performance alumina-based ceramic and boast high strength, good thermal conductivity and excellent dimensional and electrical stability at all operating temperatures. A cost-effective alternative to metal-coated reflectors, ceramic reflectors are also resistant to chemical attack and, when sealed with one of Morgan’s glazes, benefit from an increased life span and reduced total cost of ownership.

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

July 2014

Morgan Advanced Materials (Morgan) 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.

Advanced Thinking in Advanced Materials www.morganadvancedmaterials.com

August 2014

New Precision Possibilities with Morgan The University of Manchester partners with Morgan Advanced Materials for graphene developmentMorgan Advanced Materials has announced a new joint development agreement with The University of Manchester, aimed at scaling up a new process for manufacturing graphene – a one-atom thick carbon allotrope first isolated at the university ten years ago and for which two Nobel Prizes were awarded.

The world’s thinnest material and a potent conductor, graphene is also extremely lightweight, chemically inert and has a large surface area which means, with further research and testing, it could change the way we think about electrical and chemical engineering.

Bringing together some of the University ’s leading graphene researchers and Morgan’s 150 years of carbon processing expertise, the partnership will explore the full potential of graphene, with a particular interest in understanding and optimising the relationship between the manufacturing process and materials science.

The partnership has been established to improve the prospects of bringing this material to commercial reality. Morgan initially began work with The University of Manchester in early 2010 on a number of Government-funded materials and related programmes, and the joint graphene development agreement represents the next stage in this relationship.

The University of Manchester, the home of graphene, was where the scientific discovery was made. It has around 200 graphene researchers and is a world leader in applied and fundamental graphene research.

The £61m National Graphene Institute at the University is set to open in early 2015, funded by £38m from the Engineering and Physical Sciences Research Council and £23m from the European Regional Development Fund. The integrated Morgan and University academic team will therefore be working within a significant community of graphene expertise and facilities.

Dr Mike Murray, Chief Technology Officer of Morgan Advanced Materials commented: “With decades of expertise in developing specialist carbon-based materials, Morgan’s material scientists will be based full time at the university, working closely with academic colleagues to understand the manufacturing mechanism and properties of graphene, helping us explore the applications where the technology can be used for optimum benefit.” Clive Rowland, CEO of the University ’s Innovation Company, UMI3, added: “To explore and fully exploit the properties of graphene, commercial partnerships are vital. I am very pleased with our collaboration with Morgan, which is based around an intellectual property project that we have taken to the proof-of-principle stage. We have consistently said that joining forces with world-class companies like Morgan Advanced Materials and tapping into such engineering and industrial experience will help us realise the full potential of the material and greatly assist us in overcoming the myriad challenges of taking an entirely new material from the laboratory all the way through to the manufacturing stage and ultimately to market adoption.”

August 2014

8 9

Morgan Advanced Materials is challenging customers to take advantage of its expertise in supplying technical ceramic products to extreme levels of precision and accuracy. Sustained investment by the company in both capacity and skills means Morgan can design components combining microscopic levels of precision with the unique electrical and mechanical performance properties of ceramic materials.

Morgan manufactures its own range of high-purity alumina materials, with the company’s proprietary manufacturing techniques allowing it to produce alumina ceramic components to single micron tolerances. These components are used in a wide range of high-performance applications, including analytical and scientific instruments and semi-conductor processing, in which precision is of prime importance.

Quadrupole saddles provide a typical example of how the quality and accuracy of Morgan’s manufacturing and production is being put to practical use. Quadrupole saddles, also known as quadrupole alignment discs, are used in mass spectrometers used by scientists to identify the types and quantities of molecule present in a substance, and to analyse these at an atomic level, for example during drug or chemical analysis or food standards testing. Morgan supplies quadrupole saddles to 0.001mm tolerance - 100 times smaller than the thickness of the average human hair. This astonishing precision, combined with the superior material properties of Morgan’s own manufactured ceramicoptimises the accuracy and performance of the mass spectrometer. These elements are crucial to the high-performance applications in which technical ceramics are typically used. In such settings,

using sub-optimal ceramic materials may at best result in extended set-up

and testing time, and at worst render the

instrument incapable of meeting the specification.

Tony Beswick at Morgan Advanced Materials, points out that while Morgan is aware of many uses for technical ceramics of such exceptional quality, the possibilities may in fact be far greater. “We know the demand for high-accuracy ceramic components is considerable and growing,” he says.

“Morgan has a long history of producing standard and custom-designed components for scientific and analytical equipment, but we suspect this may be just the tip of the iceberg. We can now provide technical ceramic products made within very tight tolerances, from high-performance materials, thanks to our own proprietary processes, and furthermore we have the expertise to work with clients to design and produce bespoke solutions. If anybody out there can think of a new challenge, a new way to use this capability, we would be very interested to hear from them.”

Morgan also produces standard and custom designed metal–to-ceramic feedthroughs and brazed assemblies, providing technical solutions for a wide range of applications and markets.

Advanced Thinking in Advanced Materials www.morganadvancedmaterials.com10 11

Morgan and Bloodhound gearing up for land speed record attemptDevelopment work is speeding ahead at Morgan Advanced Materials (Morgan) on a series of ballistic protection panels for the Bloodhound Supersonic Car (SSC) team pursuing the world land speed record, ahead of an ambitious attempt in 2015.

Commissioned by the British-based Bloodhound team to develop custom parts for various applications from the vehicle’s ‘nose to tail’, Morgan has created a bespoke solution for the cockpit and driver monocoque, using its unique capability to produce curved shape panels for ballistic protection.

Chris Pedlingham, Lead Engineer for Commercial Composites at Morgan commented: “Drawing on our decades of experience in both vehicle and personal protection solutions, we have developed a customised lightweight composite armour system which will protect the pilot from any debris picked up by the wheels. The specification for the protection panels is, however, different to any military standard as, travelling at more than 1,000mph, even tiny fragments of rock could become a dangerous projectile.

“Using our knowledge of ultra-lightweight protective components, we developed product-specific test methods to replicate the unique in-service conditions which the panels will have to withstand, resulting in a ballistic protection panel which is ideally suited to the challenges of the project.”

Stringent testing, carried out at Morgan’s ISO 17025-accredited laboratory, has included the use of high-speed video analysis to optimise the panels for minimum weight, essential in a speed record attempt.

Conor La Grue of the Bloodhound SSC team added: “Our key technology supply chain partners such as Morgan were carefully selected based on their expertise and capacity to create innovative solutions for a truly unique challenge. We are now well into the primary structure build of Bloodhound SCC, which includes key deliverables from Morgan. We are confident that we will be in the desert next year for high speed testing and that we will achieve a new 1,000 mph land speed record the summer after – and in the process of doing so, will be sharing this high innovation, broad technology, open source project with the world to inspire a generation of scientists, engineers, mathematicians and technologists.”

September 2014Morgan Advanced Materials is continuing to meet the unique demands of customers in the medical OEM sector, with the addition of a new capability enabling the accurate measurement of bubble size in fluid delivery tubes using its ultrasonic air-in-line (AIL) sensors.

The presence of bubbles of any size in tubes used to convey fluids into the blood supply can be highly damaging. However, in other non-critical fluid handling applications, bubbles of a certain size may not affect the operation of the system. This means that bubbles of a known size can be allowed to pass the bubble detector without generating a ‘dry’ signal. Once above a certain threshold - which can be chosen by the user - the sensor will then see the bubble as air, generating a ‘dry’ signal.

This new technology draws on Morgan’s extensive experience in ultrasonic transducers and uses a bespoke system of electronics that can be tuned to exact customer requirements. In medical applications, the tube diameter is not restricted, but the technology is currently available off the shelf for 2-7mm tubes. The new capability extends the versatility of Morgan’s AIL sensors and was initially developed in response to more exacting requirements being driven by the Food and Drug Administration (FDA). Oliver Ridd, Graduate Engineer at Morgan Advanced Materials, explained: “Many delivery systems on the market operate via a simple ‘go/ no go’ system meaning they are frequently being

shut off if a bubble of any size is detected by the AIL sensor. However, in some applications, very small bubbles do not present a danger and there is no need for flow to be interrupted. “The threshold at which shut-off is needed can vary depending on the application. As well as detecting bubbles ranging from a few microlitres to several millimetres in size, our sensors are able to fulfil the requirement of detecting foam as air. The new capability has been evaluated with our line of standard sensors but will be available as part of any individual solution for new customers, and can be tuned specifically to their requirements.”

Morgan announces improvements in air-in-line bubble detection capabilities September 2014

HotRodTM sheaths from Morgan Molten Metal Systems offer superior thermocouple protection and easy installationMorgan’s Molten Metal Systems business announces its HotRod™ pyrometry sheaths and other pyrometer assembly products, which protect thermocouples in furnace heating control systems. Industry proven for over 30 years, the pyrometer assemblies are made of a durable, erosion-resistant clay-graphite mix with special plasticity properties, which is then extruded into the proper shape. The pryometer assemblies are designed to have a metal wire inserted into them, and are then put into a metal bath to measure the temperature. HotRod sheaths are designed for used in furnaces and other high temperature environments, and are supplied with a ½” (12.7mm) threaded steel tube for quick and easy attachment to the furnace pyrometry system.

The pyrometer assemblies are durable, with a glaze on the ceramic exterior that protects the product from oxidation, thereby reducing downtime. These assemblies offer effective thermocouple protection with high thermal conductivity for fast, accurate temperature readings and reduced fuel consumption.

Single pyrotubes are heat resistant to 1600°C, while the HotRod sheaths with inner steel tubes are resistant to 1000°C and are typically used for aluminum applications. HotRod products require no special tools for installation.

September 2014

11 13Advanced Thinking in Advanced Materials www.morganadvancedmaterials.com12 13

Harsh environment challenges are no problem for Morgan Ultrasonic Sensors

Sustained investment and innovation are once again paying off for Morgan Advanced Materials, this time in the field of sensing solutions. Morgan can now offer customers customised and optimised sensors for use in harsh environments. Products available include liquid and gas flow measurement and level / distance detection, while additional ultrasonic assessments can be made including the identification of fluid “quality” and chemical concentration. This marks a major step forward in a number of markets which each present a unique set of technical challenges.

The latest example of Morgan’s class-leading expertise in harsh environment technology comes in the form of its ultrasonic level sensors, which are applicable to a surprisingly large and diverse range of settings. These include automotive, aerospace, rail, marine, medical, pharmaceutical, industrial, chemical, oil and gas and food / brewing applications. One of the reasons why ultrasonic sensors are so popular when used with liquids is their inherent tolerance to contamination from particles, ice crystals, foam and fluid opacity.

In light of this market diversity, Morgan’s harsh environment solutions are manufactured to give optimal performance in each specific application. For example, in the aerospace sector, accuracy in distance and level measurement has been demonstrated in service for the last 20 years. Aerospace requirements typically include tolerance to shock and vibration, large temperature variations and lightning strikes without compromise to sensor performance. When used in fuel and liquid handling technology, sensors must also be able to withstand permanent immersion in aggressive fluids and high and / or low pressures.

They may be characterised and optimised over a wide range of operating conditions to ensure continuous and reliable operation. In subsea environments, sensors must resist extreme levels of pressure, which make great demands on the ceramic materials used and the toughness and durability of the units manufactured.

Tony Beswick of Morgan believes the company’s ability to work closely with customers who require harsh environment solutions, from concept and preliminary trial phases right through to optimisation and qualification phases, offers a wealth of possibilities for both parties involved. “Our engineering, design and development expertise enables us to provide customised solutions that exactly meet customers’ needs. We know harsh environment markets well, and have spent years deliberately extending our experience and capabilities in this area. As a result we can optimise each of our products for its specific application, for example complimentary elements may be added or materials revised according to the destined environment. However, there is no room for complacency and there may well be applications for our capabilities that we have not thought of yet. If anybody wants us to solve a novel challenge within a harsh environment, we would be delighted to hear from them,” he says.

Morgan Advanced Materials has its own cutting-edge assembly, integration and test facilities, so harsh environment technologies can be tested, optimised, and characterised across wide operational conditions to make sure that the precise requirements of each customer are met.

September 2014

Morgan’s Electrical Carbon business announces that it offers high quality, expertly designed rotary transfer systems, or rotary joints, for a wide range of applications. The rotary transfer systems, featuring high performance engineering, are electromechanical products for the transfer of currents, electrical signals or media from a fixed to a continuously rotating part.

Rotary transfer systems from Morgan offer reliable, high-speed transfer of data transfer in constantly rotating systems. Morgan manufactures a variety of slip rings, which are designed to transfer current, electrical signals or other media from a fixed part to one that is continuously rotating and are used in designs that require a rotational movement

of more than 360° without the hindrance of a drag chain. Also available are complete rotary unions, which provide a seal between a stationary supply pipe and a rotating part such as a drum, cylinder, or spindle, to permit the flow of a fluid into and/or out of a rotating part, and media distributors, which transfer liquid or gaseous media from stationary to continuously rotating elements.

All the standard systems can be combined with each other to form hybrid systems to meet specific customer needs. The modular nature of these products offers Morgan’s customers economic solutions with the greatest possible flexibility. The systems are engineered to meet customer requirements and are backed by a comprehensive, global, technical support network.

Morgan’s Electrical Carbon business offers expertly designed, modular rotary transfer systems

September 2014

Morgan announces availability of extensive range of PZT materials and advanced cutting, dicing and grinding capabilities

Morgan Advanced Materials (Morgan) announces the availability of PZT (lead zirconate titanate) components, and assemblies at its Bedford, Ohio facility. Also offered are advanced PZT dicing, cutting, and grinding capabilities. The materials are ideal for use in consumer and high volume electronics, semi-conductor, medical, SONAR (commercial and defense) and oil and gas markets.

The ISO 9001 and ISO 14001 compliant facility offers more than 30 compositions of PZT material in Navy Type I, II, III, V and VI variations. Morgan also manufactures unique materials in its standard material range with enhanced piezoelectric, permittivity, coupling, and aging rate properties. A dedicated team of technicians and transducer and composite engineers take projects from drawings to finished product, and from development to in-service and volume production.

In addition to its extensive material portfolio, the facility has strong PZT dicing and cutting capabilities, including the availability of dicing machines in clean rooms, ideal for customers

requiring components for electronics, semi-conductor and medical markets. Morgan can dice sections with thicknesses of 0.006-0.360 inches and can cut up to 1-inch thick PZT. This allows the company to offer both very small and large plate dicing capabilities to tight tolerance and very clean finishes.

Dicing high precision, high and low frequency 1-3 and 2-2 composites ranging from 10 MHz to 100 kHz (0.0078-1-inch) is also performed, with a variety of choices of backfill materials to suit customers’ specific applications.

Metallization of electrodes is another specialty, including use of sputtered materials like gold, nickel chromium, nickel vanadium, and aluminum. The facility processes fired-on silver (on standard PZT only), silver epoxy alternatives, and electroless nickel for electrical connections. Unique grinding capabilities mean Morgan can fine grind to thicknesses of 0.0030-inches for very thin plates and high frequency 1-3 composite designs, raising frequency capabilities up to 30MHz.

September 2014

FireMaster® FireBarrier™135 from Morgan chosen to help protect major new Italian tunnel development

For many years now, the engineering world has sought innovative yet effective solutions to the problems of ensuring safety in road tunnels, and in particular protection against the constant threat of fire. Now, thanks to the use of FireMaster®

FireBarrier™ 135 from Morgan Advanced Materials, the users of one key road tunnel in central Italy are thoroughly protected.

The Serralunga tunnel runs for 1300m near the mountain town of Rocca di Cambio, in Italy, connecting the popular ski resorts of Campo Felice with the Plateau Rocche via the motorway system. Built at an altitude of 1600m, the Serralunga tunnel has a gradient of 4.5% and was opened to traffic in December 2013.

Fire in road tunnels can have catastrophic consequences; not only does it threaten human life, but it can cause huge damage to the tunnel’s structure, in some cases resulting in collapse. Furthermore, fires in tunnels burn at extremely high temperatures; a typical tunnel car fire reaches 400°C, but a large petrol tanker fire may reach 1400°C. Therefore, all tunnels must offer protection sufficient to deal with these events.

The Serralunga Tunnel has two escape routes, which take the form of suspended paths. The challenge that faced the design team working on this project was lining those escape paths with a material that could withstand extremely high temperatures, protecting both the tunnel’s structure and the people within from the ravages of fire and the effects of smoke. Having considered all options, they chose to use FireMaster FireBarrier 135 from Morgan Advanced Materials, supplied through specialist installer Kapyfract AG.

FireMaster FireBarrier 135 is one of the most extensively fire-tested products available for this purpose, and can be applied either in the form of pre-cast sheets, or by spraying to a substrate attached to the tunnel. In the Serralunga tunnel, the product has been applied over a galvanised wire mesh, allowing it to reach every part of the tunnel surface. FireBarrier 135 has very high adhesion capacity, so very little of the material is lost during application. FireBarrier 135 goes on in a single application - a mere 36mm thickness was ideal for the Serralunga work - and dries quickly, a particular advantage in the Serralunga project, since all parties wanted to see the tunnel open promptly.

Ermanno Magni, Technical Product Application Manager, Europe, for Morgan , is pleased with the results of the Serralunga Tunnel project. “This is only the second tunnel in Italy to use this cutting-edge technical solution, and Morgan is delighted to be leading the way in this field. The installation of FireBarrier 135 in this project was swift and straightforward and it has given a smooth and uniform finish to the tunnel escape routes. Most importantly, we know from extensive testing that the use of this product helps to ensure the safety of people using the Serralunga Tunnel, even in extreme fire conditions.”

Francesco Ferrari, specialist fire protection consultant, has also been impressed by the Serralunga project. “The treatment of the suspended escape galleries in this tunnel with FireBarrier 135 provides an extremely significant layer of protection for users of this tunnel. Its use is backed by a wealth of evidence, and installation of approximately 6,500 square feet (600m²) of protection has been achieved in under 40 days,” he commented.

September 2014

11

Trial of Morgan’s blue lightning Thermocouple assembly delivers impressive results for global automotive component manufacturer

September 2014

Trials of an alternative thermocouple sheath have delivered significant cost and time savings for a components manufacturer which caters for some of the world’s leading automotive industry operations. In tests carried out at its plant in Aurangabadin India; High Technology Transmission Systems Pvt Ltd found that thermocouple assemblies supplied by Morgan’s Molten Metal Systems business outlasted even their manufacturer’s estimated operational life, far out-performing the existing solutions available to the company.

High Technology Transmission Systems (HTTS) is part of the Endurance Group, a global force in aluminium castings for the automotive sector with 19 plants across India, Italy and Germany. A high-performance die casting (HPDC) operation, HTTS produces cast aluminium clutch assemblies and other cast components.

The company approached Morgan looking for improved performance for the thermocouple assemblies used for the continuous measurement of the temperatures in its holding furnaces. HTTS has been using two different types of assemblies, both of which had inherent shortcomings.

One is an L-shaped CI tube which lasts an average of seven to eight days. Although a low-cost option, this type of assembly requires a protective coating, which represents additional work, while the subsequent chance of metal contamination, which is very high, could compromise the quality of the end casting. The second product being used is silicon nitride (SS316) which, although it has

a recommended operational life of nine months, carries a high purchase cost and has considerably lower impact resistance, making it very vulnerable to breakage during the aluminium pouring process.

The trial involved Morgan’s innovative Blue Lightning thermocouple sheath supplied as a complete pyrometer assembly, which was installed in a 500kg furnace for a four-month period. The recommended life of the Blue Lightning is 42 to 48 days, but at the end of the 122-day trial, the sheath was still fully functional and capable of continuing in operation.

HTTS maintenance manager Sambhaji Bachkar, who oversaw the trial, says: “The thermocouple assembly performed well throughout the trial, maintaining and controlling the temperature in the holding furnace. When we removed it from the furnace, it was still in good condition, with no signs of deterioration.”

Robustly designed for extended service life, the Blue Lightning delivered a number of benefits for HTTS, as Ramdas Chitalkar, Technology Manager at Morgan Advanced Materials explains: “Apart from the extended life of the product, it proved to be a cost-effective solution in a number of other ways. There was no need for any additional coating, which requires time and manpower, so changeover time is reduced, and there is no danger of metal contamination, which has an impact on the end quality of the casting, so the risk of rejects is minimised.”

Blue Lightning Thermocouple Sheaths are available with either a ½in BSP pipe, ¾ in NPT pipe or without a pipe as a straight ceramic sheath for higher-temperature copper applications. The pipe versions are also available as a complete pyrometer assembly to help speed up installation and reduce installation costs. The assemblies are specifically designed to provide a quick and technician-free change out of the existing pyrometer. Design features include; non-wetting chemistry for ease of cleaning, low dross build-up and elimination of metal contamination. Highly conductive, they deliver rapid response times, reduced fuel usage and good thermal shock resistance. The assemblies can be used in applications which require either a fixed or a floating pyrometer.

Advanced Thinking in Advanced Materials www.morganadvancedmaterials.com14 15

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

Europe Morgan Advanced MaterialsMorgan DriveStourport-on-SevernWorcestershire DY13 8DWUnited Kingdom

T +44 (0) 1299 872210 F +44 (0) 1299 872218 europesales@morganplc.com

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

T +65 6595 0000 F +65 6595 0005 asiasales@morganplc.com

South AmericaMorgan Advanced MaterialsAvenida do Taboão 3265- SãoBernardo do Campo - SPCEP 09656 000Brasil

T +55 (11) 4075 0400 F +55 (11) 4075 7547 sasales@morganplc.com

North AmericaMorgan Advanced Materials4000 Westchase BoulevardSuite 170, Raleigh,NC 27607-3970USA

T +1 (855) 809 9571 F +1 (706) 622 4424 nasales@morganplc.com

Morgan Advanced Materials plcQuadrant, 55-57 High Street, Windsor, Berkshire, SL4 1LP United Kingdom

Copyright 04.2014 Designed and Produced by Morgan Advanced Materials www.morganadvancedmaterials.com

A B O U T M O R G A N A D VA N C E D M AT E R I A L S

LISTED ONTHE LONDON

STOCK EXCHANGE

MANUFACTURING IN

>30COUNTRIES

OVER

9,000EMPLOYEES

SELLING INTO

>100COUNTRIES

Morgan Advanced Materials is a global engineering company offering world-leading competencies in materials science, specialist manufacturing and applications engineering.

We focus our resources on the delivery of products that help our customers to solve technically challenging Problems, enabling them to address global trends such as energy demand, advances in healthcare and environmental

sustainability.

What differentiates us?• Advanced material science and processing capabilities • Extensive applications engineering experience

• A strong history of innovation and reinvention • Consistent and reliable performance• A truly global footprint • We find and invest in the best people