AEROBRAZE ENGINEERED TECHNOLOGIESSTRATEGIC COLLABORATION FOR SMART INNOVATION

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AEROBRAZE ENGINEERED TECHNOLOGIES

TRUSTED, CUSTOMISED EXPERTISE THAT RESULTS IN SMART INNOVATION AND SHARED GROWTHAerobraze Engineered Technologies (AET) is a specialised business unit of Wall Colmonoy Limited with expertise in spray and fuse, PTA and HVOF deposition processes; vacuum brazing, vacuum heat treatment; fluoride cleaning, welding and repair of aircraft turbine engine components.

Aerobraze serves an international customer base in the aerospace, oil & gas, automotive, steel and nuclear industries throughout Europe, MENA, South Africa and India.

AET is known for its unique proven way of creating tailor-made solutions. We pride ourselves on long-term strategic customer collaboration that produces value-added ideas and creative solutions.

Combining over 45 years of engineering technology with a progressive, visionary outlook, Aerobraze Engineered Technologies offers customers the kind of trusted, customised expertise that results in smart innovation and shared growth. Aerobraze maintains quality approvals meeting the high standards of the aerospace industry. Its quality management system is accredited to ISO9001, AS9100, Rolls-Royce and many customer specific approvals. Special Process approvals are held within Nadcap for Brazing, Heat Treatment, and Welding. The facility is also registered to the Environmental Standard, ISO 14001.

HELPING CUSTOMERS MAINTAIN AN EDGE

To help our customers stay ahead of the competition, we maintain steady investment in research and development, continually generating new products, technologies and solutions.

Taking a proactive stance, we join forces with customers, major universities, metallurgical laboratories and local governments to conduct research, resulting in breakthrough products often setting the stage for advancements in a range of industries.

From Brazing to Heat Treating to Surfacing to Coatings to Welding and Machining, we provide: • Technical Assistance and Expertise

• Metallurgical Coatings

• Brazing Alloy Development and

Application

• Heat Treatment – the largest

commercially available vacuum furnace

in Europe

• Full Range of Machining Requirements

• Weld Repair Solutions

Working in collaborative partnerships with our customers, we know how important

it is to cost efficiently, develop solutions and products that last.

Below: Measuring the length of a Bush with height meterLeft: HVOF Spraying, Right: Colmonoy 625 Laser Cladded (image courtesy of AMB Lab, University of Birmingham)

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WHAT WE DO

OFFERING A COMPLETE SOLUTION

Brazing, Heat Treatment and Coating

• Vacuum Brazing, Fusion and

Heat Treatment

• Hydrogen, Argon and Torch Brazing

• Hydrogen Atmosphere Brazing

• Hydrogen Fluoride Cleaning

• Seal Segments (Honeycomb)

• WallCarb

• Roller Coating

Maintenance, Repair & Overhaul (MRO)

• Gas turbine engine weld repair

• Weld modification and welding on new

manufacture parts for civil and military,

aero, land and marine gas turbines

• All alloy systems weld repaired including

super nickel alloys, single crystal, titanium,

stainless steels, cobalt, aluminium and

magnesium

Prototype, Process Development

• Vast experience in generating First Article

Inspection Repairs on many aero-engine

types and writing new weld Repair

Schemes where customer Repair Schemes

do not exist particularly for quarantined,

engine-run components.

Equipment Used

• Fusewelder® Torch

• Model J3 Spraywelder™ System

• NicroSpray® System

• JP8000 HVOF System

• Powder Dispenser (Seal Segment)

• Co-arc Wire Spray

• Discharge Welder

• Hydrogen Furnaces

• Vacuum Furnaces (V1, V2, V20, V50 and

V84)

• Interpulse Heat Management System

• DPI/FPI

HIGH-PERFORMANCE, HIGH-VALUE, HARDSURFACING, WEAR RESISTANT COATINGS

• High Velocity Oxy Fuel (HVOF)

• Plasma Transferred Arc (PTA)

• Co-arc Wire Spray

• Laser Cladding*

• Flamespray

• Spray and Fuse

• Rod Welding

• TIG Welding

Typical Nickel and Cobalt Alloys:• Colmonoy® 42, 52, 62, 69, 78, 88 and 625

• Nicrobraz® 10, 30, 130, 135 and LM

• Wallex™ 6, 21, 42

Extending component service life and enhancing product performance.

Our coating engineers work with you to recommend optimal coatings

Bottom: Wear plate coating

* In conjunction with a partner

Left: Model J3 Spraywelder™ System, Right: Fusewelder™ Torch, Bottom: Wire Spraying

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AEROBRAZE ENGINEERED TECHNOLOGIES

INTEGRATED APPROACH FOR BRAZING AND HEAT TREATMENT

Our expert engineers offer a complete solution

from design and prototype to manufacture. We

can meet your brazing requirements through the

use of our nickel and copper base alloys along with

precious metals (gold and silver base).

Aerobraze offers support services, such as surface

preparation, assembly and application of alloy,

design/construction, process control and full

machining capabilities. We also provide various

welding techniques using fixturing for assembly

& fabrication. Welding techniques include TIG and

Discharge welding.

Aerobraze has one of the largest commercially

available vacuum furnaces in Europe, measuring

1.98m x 0.94m, down to our smallest 0.46m x

0.46m vacuum furnace. The furnaces are approved

for aerospace and used for a wide range of

work including vacuum stress relieving, vacuum

annealing, solution treatments, ageing processes

and high-temperature vacuum brazing.

Furnaces are available to meet your brazing and

heat treating requirements, including:

• Design of new parts for brazing

• Development of brazing procedures & processes

• Redesign of parts for optimum braze efficiency

• Furnace brazing services

We develop

• The brazing alloy

• The cycle

• The joint

Brazing Processes

• Hydrogen and Argon Furnace Brazing

• Hydrogen Atmosphere Brazing

• Hydrogen Fluoride Cleaning

• Vacuum Furnace Brazing

Brazing Components

• Heat Exchangers

• Power Industry Regenerators

• Heat Transfer Assemblies

for Aerospace and Energy

• Honeycomb Segments

DEVELOPING WELD REPAIR SOLUTIONS FOR HIGH VALUE PARTSAerobraze is an aviation standard repair facility. Aerobraze

provides OEMs with new weld repair solutions for high added

value parts. Aerobraze will prepare First Article Inspection

Repair welding procedure specification and weld data cards.

Aerobraze has highly skilled and trained personnel, experienced

in welding all alloy systems including super nickel alloys,

single crystal, titanium, stainless steels, cobalt, aluminium and

magnesium. Recurrent internal training covers gas turbine

MRO; alloy system welding metallurgy; standard practices and

product integrity awareness.

Aerobraze is Nadcap and Rolls-Royce approved. The latest TIG

welding equipment, including the gas tungsten constricted arc

welding process, is used to salvage weld repair super nickel

and single crystal alloys for the civil, military and marine gas

turbine industries.

Aerobraze Engineered Technologies’ high-temperature vacuum brazing furnaces

(various atmospheres) are designed to produce high quality brazed joints for aerospace,

oil & gas, transportation and energy industries.

Furnace Length Width Height

V1 0.97m (38.1”) 0.74m (29.1”) 0.51m (20”)

V2 1.19m (46.85”) 0.89m (35”) 0.89m (35”)

Furnace Diameter Height Additional Information

V20 0.46m (18.11”) 0.46m (18.11”)

V50 1.07m (42.12”) 1.98m (77.95”) Extendable to 2.79m (109.84”)

V84 1.98m (77.95”) 0.94m (37”)

Bottom: Honeycomb Circular Seal

Top Right: First Article Inspection Middle Right: Analysis Bottom Right: Quality Approvals

Welding • GTAW (TIG) welding

• Inter Pulse Heat Management

System

• Resistance Spot and Seam

Welding

Engine Types• Trent 500-900

• Spey (Marine)

• Tyne (Aero/Marine)

• EJ200 Euro Fighter

• WR21 Engine (Type 45

Destroyer)

Welding Approvals• Rolls-Royce RPS184

• Rolls-Royce Mil145

• ITAR

• Nadcap

Applications• Turbine Blades

• Lever Control Shaft

• Engine Bearing

• Engine Nozzle

• Combustion Ring

• Divergent Petal

Heat Treating

Welding

Note: All furnaces work to a temperature range of 550°C (1022°F) - 1200°C (2192°F)

AEROBRAZE ENGINEERED TECHNOLOGIES

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QUALITY ASSURANCEAerobraze works under Quality Management Systems.

We are committed to working closely with our customers by making sure we are

certified and approved to provide excellent service and value.

COMPLETE MACHINING REQUIREMENTSCNC Machine ShopWall Colmonoy maintains its investment program in modern cutting technology

and use of specialised machine tools for a full range of machining needs.

Programme manage your complete machining requirements with internal

Machining, Brazing, Heat Treatment, Coating, Welding, and NDT as well as

outsource other key processes.

Fast Flexible Turnaround To Meet Exact Customer Specifications

• Milling: CNC and Manual

• Turning: CNC and Manual

• EDM-Wire & Multi Axis Plunge

• Grinding: Surface, Cylindrical and Centerless

• Honing and Lapping

• CMM Inspection

Note: Third party validation can also be arranged

QMS Approval• ISO9001:2008

• AS9100:2003

Special Process Approvals

• Nadcap Brazing & Heat Treatment

• Nadcap Welding (Fusion)

Customer Approvals• Rolls-Royce Aerospace UK -

Brazing, Heat Treatment & Welding MIL-145

• Rolls-Royce Germany

• Rolls-Royce Nuclear Submarines

• Rolls-Royce RPS253

(Application of Hard-facing Alloy)

• Rolls-Royce SPEY (SP0013M)

Customer Approved Supplier Status

• Safran Power

• ONTIC

• Timet

• Cameron Ireland (Oil & Gas)

Environmental EMS Approval

• ISO14001:2004

CERTIFICATIONS & APPROVALS

Brazing, Heat Treating & Welding

INDUSTRIES SERVED

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OIL, GAS & PETROCHEMICAL

GAS TURBINES

PISTON

PLUNGERS

PUMPS

RISER PINS

VALVE HOUSINGS

NUCLEARHEAT EXCHANGERS

HEAT TREATMENT

POWER GEN / WASTE TO ENERGY

COMPRESSORS

GAS TURBINES

GENERATORS

HEAT EXCHANGERS

HONEYCOMB RINGS

MANIFOLDS

REGENERATORS

FOOD & BEVERAGEAGITATORSMIXERSSLURRIES

CEMENT / STEEL / PAPERMILLSBEARING HOUSINGS

GRID PLATES

ROLLERS / BUSHES

WEAR PLATES

FOOD & BEVERAGEAGITATORS

HOMOGENISER

MIXERS

PISTONS

AUTOMOTIVE / DIESEL ENGINECATALYTIC CONVERTER

EXHAUST GAS RECIRCULATOR (EGRS)

HEAT EXCHANGERS

RAIL

AUTO COUPLER KNUCKLES

ROCKING COLLARS

AEROSPACEAEROFOILS

DIFFUSERS

FUEL NOZZLES

HEAT EXCHANGERS

HEAT SHIELDS

VANE INSERTS

MEDICALMRI SCANNER COMPONENTS

AETB-0616500

AEROBRAZE ENGINEERED TECHNOLOGIESSTRATEGIC COLLABORATION FOR SMART INNOVATION

EUROPE: Alloy Industrial Estate | Pontardawe Swansea, Wales (U.K.) SA8 4HLTel +44 (0) 1792 862287 | Fax +44 (0) 1792 830124

CINCINNATI: 940 Redna Terrace | Cincinnati, OH 45215Tel 513-842-4200 | Fax 513-842-4266

OKLAHOMA CITY: 4700 S.E. 59th Street | Oklahoma City, OK 73135Tel: 405-672-1361 | Fax: 405-670-3763

Web www.wallcolmonoy.co.uk/aerobraze | Email aet@wallcolmonoy.co.uk

AEROBRAZE ENGINEERED TECHNOLOGIESStrategic Collaboration for Smart Innovation.

SWANSEA, WALES (U.K.) | CINCINNATI | DAYTON | OKLAHOMA CITY

The information provided herein is given as a guideline to follow. It is the responsibility of the end user to establish the process information most suitable for their specific application(s). Wall Colmonoy Limited (UK) assumes no responsibility for failure due to misuse or improper application of this product, or for any incidental damages arising out of the use of this material.

Copyright © 2016 Wall Colmonoy Limited. All rights reserved.