aerospace - mj sections - precision cold forming and ... · rings can include hydraulic stretch...
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www.mjsections.co.uk
Precision Formed & Machined
Components for Aerospace
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AerospaceHead Office
MJ Sections Ltd, Marriott Road Industrial Estate, Netherton,
Dudley, West Midlands, DY2 0JZtel: 01384 230444fax: 01384 256964
email: [email protected]
Halesowen Machining FacilityM.J Sections Ltd,
130 Stourbridge Road, Halesowen, B63 3UN
tel: 01384 230444fax: 01384 256964
email: [email protected]
Precision Formed & Machined Components for Aerospace
Part of MJ Sections Aerospace Group Ltd
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MJ SECTIONS LOGO 2015v3.pdf 5/5/15 12:30:45
Part of MJ Sections Aerospace Group Ltd
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MJ SECTIONS LOGO 2015v3.pdf 5/5/15 12:30:45
Precision Formed & Machined Components for Aerospace
Part of MJ Sections Aerospace Group Ltd
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MJ SECTIONS LOGO 2015v3.pdf 5/5/15 12:30:45
Precision Formed & Machined Components for Aerospace
MONOGRAM & WORDMARK
MJ SECTIONS LTDMJ SECTIONS LTD
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AdvancedRoll Forming
Machining
Electro DischargeMachining
Honeycomb Rings
Welding
Heat Treatment
Hot Forming
Pressing and Fabrication
NDT
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Celebrating 35 years of engineering innovation, we are a global market leader working in partnership with the aerospace industry.
Precision Formed and Machined Components for Aerospace
www.mjsections.co.uk
Part of MJ Sections Aerospace Group Ltd
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MJ SECTIONS LOGO 2015v3.pdf 5/5/15 12:30:45
MONOGRAM & WORDMARK
MJ SECTIONS LTDMJ SECTIONS LTD
Display panel 2.indd 1 07/05/2015 14:55
Rolled Rings & Section
Contour Rolling
Precision Roll Forming and Fabrication
Complex profiles are manufactured from a wide
range of sheet and coil materials including the latest
generation of nickel based alloys and titanium beta
alloys. Sections for structural and non-structural
applications are produced on specialist multi-stage
machines capable of dimensional accuracy to
0.1mm or better.
Welded Rings
Circular section can be produced open ended or
welded into a closed ring. The processing of welded
rings can include hydraulic stretch forming to
achieve close tolerance diameters or other features.
Rings of 50mm to 3,7m diameter are produced for a
variety of applications including fairings, heat shields,
combustors and fuselage frames.
Straight Section
Straight rolled section can be supplied by length
for further processing by the customer or as finished
details for final assembly. Lengths not exceeding 7m
can be controlled stretched to enhance
mechanical properties or to achieve high levels
of straightness. Typical applications would include
stringers and stiffeners for airframe fuselage and
wing structures, sealing strips and seal retainers.
Using our specialist rolling techniques we are able
to replace forged and machined rings with rolled
sheet metal profiles.
Complex profiles can be achieved by combining
several rings (now with near zero t bend radii) and
joining them together by welding or brazing. We
can also add features such as anti rotation lugs,
wear pads, threaded bosses etc as required.
Very close tolerance dimensions can also be
achieved by conventional or electro discharge
machining where necessary.
This offers dramatically reduced lead times and
a much lower total cost of acquisition for our
customers.
Rolled Bar & Tube
Hot FormingWhere an application requires high strength materials
which cannot be formed conventionally, for example
6AL4V and 6-2-4-2 titanium, hot forming allows us to
overcome this. Induction heating will raise the
temperature of titanium casings from ambient to
680deg centigrade in around one minute, allowing the
forming process to commence.
Alternative hot forming processes include hot pressing
and die quenching, achieving shapes that would
otherwise be impossible from these exotic materials.
Offering significant savings in cost and lead time, roll
formed bar can be welded and hydraulically sized to
provide an effective alternative to forgings or flash-butt
welded rings (FWR). The testing of Group 1 welds emulates
FWR practice to assure equivalent product integrity.
Roll formed bar and tube can be supplied as a basic
product, proof machined or as fully finished parts.
Honeycomb Rings
As part of our ‘one stop shop’ philosophy, we
procure honeycomb, braze it to our sheet metal rolled
and expanded rings, and EDM grind the final diameters
to very close tolerances. These components offer
extremely rigid rings with numerous applications
including sealing rings used in gas turbine jet engines.
Pressing
Welding
The Press Shop comprises both hydraulic
and mechanical presses with capacity up
to 150T and a bed size of up to
711 x 890mm.
Our hot forming facility (induction and
convection) allows us to form exotic
titanium materials that cannot be
processed by conventional cold forming.
MJ Sections offers fusion TIG, resistance welding
(spot and stitch) and automatic orbital and
longitudinal TIG welding. Our aerospace welders
are approved for titanium, nickel and cobalt based
alloys, stainless steel and ferritic alloys. Material
thickness ranges from 0,25mm to 50mm.
Precision Forming and Fabrication
Adhesive Bonding
Our adhesive bonding facility operates in controlled
environmental conditions.
Processes include:
n One part cold curing Silicone Adhesive
n Two part hot curing Epoxide Paste Adhesive.
n Producing small or medium-sized assemblies of metallic
and non-metallic components.
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By combining the skills of our core manufacturing areas (rolling/sheet metal, press work and machining) we
produce both large and small fabrications, assembling detail parts together by welding (fusion and resistance),
brazing, riveting and bonding.
Through eliminating sheet metal and machining
sub-tiers, we offer:
n Integrated project management
n Simplified purchasing and scheduling
n Elimination of all intermediate logistics uncertainties
n Reduction in lead-time
n Effective cost control
n Overall cost savings
Fabrication
Machining
Our Machine Shop manufactures a diverse range of products by CNC turning and multi-axis milling.
Components are produced from basic wrought materials, plate, bar forgings, castings and roll formed
profiles manufactured in-house.
Typical components produced consist of:
Pipe end fittings, shrouds, brackets and sealing rings to an accuracy of 8 microns, from the smallest
diameter to approx 1900mm (75”) diameter.
MJ Sections Ltd has continued to invest heavily in new capital plant and equipment. This has resulted in
growing our machining capabilities and creating our own dedicated machining facility in Halesowen.
Working with five axis CNC machining, sliding head, turn / mill / drill CNC machining, and CNC turning
machines, has enabled us to expand our processes and capabilities to offer a truly one-stop-shop for your
machining requirements.
Precision Machining and Design
Machining
Design
Our team of trained & experienced engineers provide tool design and manufacturing solutions for our
products. We work closely with our customers at design stage to ensure that the product is being
manufactured with the lowest possible cost.
Alongside this, the use of Production Part Approval
Process (PPAP) on all new product introduction
allows us to guarantee repeatability, by ensuring
that the manufacturing method and tooling offers
process capability, from initial development volumes,
through to full ramp up of production volumes.
Precision Machining and Design
EDM
Electro Discharge Ltd is part of the MJ Sections Aerospace Group offering electro discharge
machining, spark eroding and wire cutting to a diverse group of industries including aerospace,
motor sport, nuclear and oil.
We offer the latest technology and the largest wirecutting machine in the UK.
Precision Machining and Inspection
Our wire and spark erosion machines are able to carry out automatic operations at speed, to close
tolerances in a lights out situation, multi-axis CNC EDM machines with toolchangers and the recent
addition of CNC EDM fast hole drilling machines enhance our existing operations. We feel that we
are well placed to meet any demand from present and new
customers, ensuring complete satisfaction.
n Five-axis wire erosion (submerged)
n CNC and conventional spark erosion
n Fast hole drilling
With full tool room facilities to manufacture complete if required.
The following list of features produced by Electro-Discharge Ltd is very important, when considering the use
of our time and money saving 24 hour / seven day a week service.
n Solution to the difficult machining of work hardening materials
n The more exotic the material the better the savings
n Better material utilisation
n Low force enables the cutting of very thin materials (as little as 0.05mm thick)
n Minimal radii as low as .08mm is possible
n Complex geometric forms and shapes – Flat to tapered surfaces
n Tapered forms with different shapes at either end (see photo above right – actually the same part!)
n Helical internal / external profiles
n Trapisoidal and multi-start thread forms for mould tools
n Quality surface textures to your requirements
Precision Machining and Inspection
Our quality system is NADCAP Accredited to AS7116, AS9100 REV:C,
ISO 9001-2008 and Rolls-Royce SABRe:9000.
We utilise the latest Solid Works, CATIA5, and PEPS programming
software, programs/drawings can be electronically transferred in IGIS or DXF
formats so that the exact sizes can be obtained.
EDM
The vacuum furnace utilises the latest PC
and PLC based control and data logging
ensuring compliance with current
aerospace quality standards AMS 2750,
NADCAP, RPS 953.
Typical Thermal Treatments include:
n Harden and Temper
n Annealing and stress Relieving
n Solution treatment and Precipitation
Heat Treatment
In 2014, as part of the company’s policy to continue to invest in new capital plant and processes, we
installed a new heat treatment facility. The plant utilises the latest TAV vacuum heat treatment furnaces
capable of thermal processes up to 1300°C with multiple options of quench gas. We are currently able
to process parts ranging from small components up to 1.2 metres. We also benefit from on site hardness
testing which means most products are ready for collection within an hour of being removed from the
furnace.
NADCAP approved Thermal Processes
Testing
Hardness testing is available with our
Mitutoyo Hardness testing machine.
n Macro hardness testing 1kg - 20kg
n Minimum reading of 0.1 microns
allowing small indentations to be
measured with high precision.
n Conversions from other hardness
testing scales.
n Current quality standards conform to
NADCAP, ASTM E384, RPS 9969.
n UKAS calibrated.
NDT Inspection
Fluorescent Penetrant Inspection (FPI) or Dye Penetrant Inspection (DPI)
Fluorescent Penetrant Inspection is carried out using custom made equipment capable of handling parts
up to a maximum of 6ft diameter.
Inspection is carried out to fully approved techniques by our operators who are qualified to NAS410 and
EN4179.
We are NADCAP Accredited and use the following dyes to carry out inspection:
n Fluorescent LEVEL 2 Water washable penetrants
n Fluorescent LEVEL 2 Post emulsifiable penetrants
n Fluorescent LEVEL 3 Water washable penetrants
Inspection of Precision Components
Magnetic Particle Inspection (MPI)
Magnetic Particle Inspection is carried out using a Magnaflux bench unit capable of a maximum output
of 3500 Amps AC RMS and 3500 Amps HWDC.
Techniques utilised include Threader Bar, Rigid Coil, Current Flow and Mag Flux, These techniques enable
us to inspect a large variety of parts from large diameter rings to shafts up to 3ft long.
Our facility is capable of inspecting parts, not only for Aerospace but also Automotive, Marine and Space.
Our operators are qualified up to ASNT Level 3 and Level 2 to EN4179 and NAS 410. We are NADCAP
Accredited for Magnetic Particle Inspection.
CMM Inspection
Inspection of Precision Components
CMM INSPECTION
The latest 3D modelling software allows us to inspect complex formed and machined components to the
customer requirements. We have the ability to import customer supplied models as well as generate our
own. Fully automated CMM machines at both facilities give
speedy and accurate measurement results which if required
can be printed or sent to the customer electronically prior
to delivery.
www.mjsections.co.uk
Head OfficeMJ Sections Ltd,
Marriott Road Industrial Estate, Netherton, Dudley, West Midlands, DY2 0JZ
tel: 01384 230444fax: 01384 256964
email: [email protected]
Halesowen Machining FacilityM.J Sections Ltd,
130 Stourbridge Road, Halesowen, B63 3UN
tel: 01384 230444fax: 01384 256964
email: [email protected]
Unit 14 Bagley Industrial Park Northfield Road,
Netherton, Dudley, West Midlands. DY2 9DY
tel. 01384 238451fax. 01384 245971
www.electro-discharge.co.uk
Precision Formed & Machined Components for Aerospace
electro dischargePRECISION WIRE & SPARK EROSION ENGINEERS
electro dischargePRECISION WIRE & SPARK EROSION ENGINEERS
MJ Sections LtdMJ Sections Ltd
Precision Formed and Machined Components for Aerospace
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