Of all the considerations that go into manufacturing your product, the most important is that it simply meets all your specifications—the more demanding the application, the more crucial it is to meet each one. That’s why we offer a wide variety of testing services:

• Mechanical testing: Tensile, compression, fatigue, bend and crack toughness—at temperatures as high as 2,500°C and under vacuums in the 5 x 10

-5 torr range

• Creep testing and aging: Temperatures as high as 2,000°C and at atmospheres from ambient to vacuums in the 10

-10 torr range, to measure time-related changes in alloys

• Rockwell hardness testing

• Corrosion testing

• Thermal cycling (freeze/thaw) and thermal shock qualification testing

• Pressure cycle testing

• Thermal performance and hydrodynamic testing (air and liquid fluid flow/pressure drop)

• Mechanical Drop Testing (up to 4000 lbs.)

• Leak/proof/burst testing and hydrostatic to 10,000 psig

• Specialty o-ring material testing for commercial nuclear plant applications. Precise temperature and water pressure control used to assure the product meets all specifications.

If your application is truly demanding or unique, we can work with you to develop a custom test protocol to evaluate your product using application-based parameters.

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MATERIALS AND PRODUCT PERFORMANCE TESTING

MATERIALS ANALYSIS SERVICES

You can obtain precise microstructural analysis, scanning electron microscopy, hardness testing and residual gas analysis of processes from Thermacore’s Materials Technology division—a single source trusted for experience, specialized knowledge and attention to detail.

MATERIALS TECHNOLOGY MEETS EXTREME PERFORMANCE

When extreme conditions threaten performance, Thermacore’s Materials Technology Division (MTD) has the unique materials capabilities to design, develop and manufacture your mission-critical application solution. From the analysis and characterization of materials to custom alloy processing and finished product manufacturing, you’ll find Thermacore technology in a wide array of applications, including ultra-high-speed flight vehicles, armaments, advanced medical devices and data centers.

Whether it's a custom specialty alloy melt for high-strength applications, high-temperature creep testing at 2,000°C (3,600°F) under a near-space level vacuum, or aluminum brazing of heat exchangers, our unique material development and processing capabilities will let you break through your material and thermal barriers.

Our Materials Technology division services include:

• A Breadth of Joining Services: Soldering, brazing, welding, adhesive bonding, diffusion bonding and fusing

• Processing: Cold isostatic pressing; sintering; high-strain-rate forging and extruding; out-of-autoclave and autoclave processing; swaging; DC button melting; AC vacuum arc remelting; and heat treating in vacuum, gases and air

• Testing: High-temperature vacuum tensile, fatigue and compression testing; impact testing; corrosion testing; hydrostatic ultra-low vacuum creep testing and aging; several forms of helium testing, including vacuum leak check; and drop testing—even O-ring material qualification capabilities

• Materials Analysis Services: Metallography, scanning electron microscopy, hardness testing and residual gas analyzing

• Specialized Processes: Such as cryomilling of aluminum or magnesium alloy powders in liquid nitrogen or argon

• Development and Consultation Services: Refractory alloy development through button melting, vacuum arc remelting, and other melting and processing capabilities; composite material and process development; consultation on failure analysis and mechanical design

• Manufacturing Services: Including product build-to-print, fabrication, assembly, and system integration. Other related services include supply chain management, total quality assurance (identification of KPIs & ongoing measurement), product validation and performance testing

COMPOSITES

For customers needing to develop and/or manufacture advanced composite materials, our contract R&D and design analysis services, prototyping, testing and validation process, and low-scale manufacturing capabilities can develop solutions for a wide range of composites in a broad array of applications. For example, our contract R&D services have been used for such diverse applications as: hypersonic materials, naval applications, armor/survivability and automotive/ground vehicle.

Expertise in the characteristics and performance of composites gives us a deep understanding of customer problems. We work as partners to provide the engineering and design teamwork

needed to create solutions using today’s advanced composite materials, such as:

Composites: • Graphite• Carbon (organic fiber)• Glass (inorganic fiber) • Thermoplastic and thermoset matrix

High-temperature Composites: • Carbon-carbon• Ceramic matrix

BRAZING AND DISSIMILAR MATERIALS JOINING

Whatever your need—aluminum vacuum brazing, aluminum-controlled atmospheric brazing (CAB), high-temperature vacuum brazing, controlled welding, soldering, diffusion bonding and fusing—Thermacore can satisfy it. Our joining capabilities include fusing quartz or Pyrex® in a vacuum tight seal and gas tungsten arc welding. And our aluminum vacuum brazing capabilities take thermal and material management solutions to new levels of efficiency—allowing you to design and create better products.

We braze to AWS C3.7, Specification for Aluminum Brazing, and heat treat to AMS 2770H, Heat Treatment of Wrought Aluminum Parts. We also do many forms of leak testing and have submersion quench and spray quench capabilities. If you have a unique product vision, we have a joining or material processing method to match. The table below highlights the furnace capabilities that support this work.

Furnace Type Temperature Work Zone

Key Features°C °F (w=width, h=height,

d=depth)

Aluminum Brazing, Heat Treating, Aging

Aluminum Vacuum Brazing Furnaces (3) 650 1,200

24" w x 36" h x 48" d 48" w x 40" h x 100" d 37" w x 65" h x 144" d

Completely automated with +/- 2.8°C (5°F) uniformity with a 5 x 10-5 torr vacuum

Solution Heat Treat Furnace 540 1,000 72" w x 72" h x 72" d Automated with +/- 5.6°C (10°F) uniformity

Aging Oven 200 400 72" w x 60" h x 48" d Automated with +/- 5.6°C (10°F) uniformity

Aluminum Controlled Atmospheric Brazing (CAB) Furnace

1,000 1,830 14" w x 3.5" h Continuous belt with controlled atmospheric conditions

Curing, Soldering, Copper Sintering

Copper Sintering Furnace (1) and Bell Ovens (4) 950 1750 12" w x 6" h

(Bells-15" dia x 17" h)Continuous belt with controlled atmospheric

conditions; programmable controllers

Soldering Belt Oven 350 660 20" w x 5" h Continuous belt with controlled atmospheric conditions; programmable controllers

Soldering and Curing Box Ovens (5), with Inert Gas (2) 550+ 1020+

Solder Ovens 23" w x 20" h x 20" d

Curing Ovens 26" w x 26" h x 25" d

Programmable controllers

High Temperature Brazing and Diffusion Bonding

High-Temperature Brazing Furnace 1,900 3,450 5" d x 6" h Programmable with a 5 x 10-5 torr

vacuum to handle refractory metal alloys

Hydrogen Furnace 1,650 3,000 4" w x 4" h x 48" d Ceramic muffle

High-Temperature Brazing Furnace 1,500 2,730 12" w x 12" h x 14" d Graphite heaters with a 5 x 10-5 torr vaccuum

Induction Brazing Furnace 1,500 2,730 6" d quartz 5 x 10-5 torr—excellent for thermocouple brazing

Diffusion Bonding and Brazing Furnace 1,500 2,730 8" d x 10" h Induction-powered shell with a 5 x 10-5 torr

vacuum and a 220-ton press

Tube Furnaces with Inconel or Stainless Steel Retorts (2) 1,200 2,190 4" d and 6" d x 24" long Programmable with a 5 x 10-5 torr vacuum

In addition to the tabular listing above, Thermacore has well over a dozen furnaces used in testing, development and joining that range in temperature capability from 100s to 1,000s of degrees Centigrade.

Name Compostion Name Composition

FS-85 Nb-27Ta-10W-1Zr ASTAR 811C Ta-8W-1Re-.7Hf-.025C

T-111 Ta-8W-2Hf ASTAR 1211C Ta-12W-1Re-1Zr-.025C

T-222 Ta-9.6W-2.4Hf-0.01C ASTAR 1511C Ta-15W-1Re-1Zr-.025C

TZM Mo-.5Ti-.08Zr Vanstar 8 V-8Cr-10Ta-1Zr-.025C

B-66 Nb-5Mo-5V-1Zr Arc Jet Material W-4Re-HfC

Following the creation of a custom alloy, Thermacore will move forward with forming, characterizing and testing. The creating, forming, characterizing and testing of custom alloys for your application requires specialized equipment and processes, which Thermacore can bring to bear on your applications. This includes:

• Vacuum Arc Remelter (VAR) for better mixing and melting of high-melt temperature materials, such as rhenium and tungsten, to produce 100-pound billets

• Custom Metal Alloy Forging for shaping alloys using rolling, extruding, pressing and swaging

• Dynapak extrusion and upset forge powered by nitrogen gas rather than hydraulic pumps, forcing the target to undergo metallurgical as well as physical change. Some of the alloys are so tough that we preheat in argon to over 2,000°C and forge at temperature

• Hot press which reaches 1,500°C (induction), 5 x 10-5 torr and has 220 tons of force

• Additional specialized equipment including a button melter, variety of furnaces with assorted atmospheres, temperatures, pressures, and various metal forming and metal working equipment

CUSTOM METAL ALLOY PROCESSING

The world continuously needs new materials that are lighter, stronger and exhibit enhanced properties. That’s why customers turn to Thermacore for high-temperature and high-strength materials—crafted from a uniquely varied array of alloys and alloying elements, from aluminum to zirconium. If you need a specialized alloy to make a project happen, Thermacore’s Materials Technology Division can provide it. From the planning and design stages through development, our specialists are there to facilitate the production of your alloy.

The materials shown below were invented and/or characterized by Thermacore’s Materials Technology division and are still being produced today.

NEW CAPABILITIES IN MATERIALS PERFORMANCE

Thermacore’s broad range of capabilities expanded further in 2010 when they added the unique engineering and materials expertise of Pittsburgh Materials Technology (PMT). A company with entrepreneurial roots similar to Thermacore’s, PMT itself was begun by talented engineers who left Westinghouse in 1992.

Today, Thermacore’s Materials Technology Division (MTD) helps customers reach new heights through advanced fabrication techniques, materials and testing services. These have earned a reputation for excellence in meeting the toughest challenges, creating materials for everything from stents for human hearts to cooling Air Force and NASA space vehicles.

Through advanced materials technology processes, Thermacore provides groundbreaking approaches and engineering expertise for your most challenging applications. Every day, Thermacore applies advanced technological capabilities for leading-edge organizations worldwide.

As a global technology leader, Thermacore operates facilities throughout the United States and Europe, including state-of-the-art AS 9100 and ISO-certified manufacturing centers. And their capabilities continue to grow. Through a broad range of services, Thermacore is ready to break through your thermal and material barriers, using the latest technologies to bring your project to life.

Aluminum Vacuum Brazed Liquied-Cooled Cold Plate

info@thermacore.com www.thermacore.com

Since 1970 • AS 9100 • ISO 9001 Certified • DDTC/ITAR Registered

LOCATIONS North America

Thermacore, Inc.Technology Headquarters 780 Eden Rd. Lancaster, PA 17601, USA Phone: 717-569-6551 Fax: 717-569-8424

k Technology Division2000 Cabot Boulevard West Suite 150 Langhorne, PA 19047, USA Phone: 215-375-3035 Fax: 215-375-3040

Materials Technology Division440 Jonathan Willey Rd.Belle Vernon, PA 15012, USAPhone: 724-379-1490Fax: 412-382-7148

Europe

Thermacore Europe, Ltd. 12 Wansbeck Business Park Ashington Northumberland, UK NE63 8QW Phone: +44 (0) 1670 859 500 Fax: +44 (0) 1670 859 539

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K-Core® Cold Plate Embedded Heat Pipe Cold Plate

THERMACORE TECHNOLOGIES• Aluminum vacuum brazements

• Cold plates

• Heat exchangers

• Heat pipe and loop heat pipe assemblies

• Heat spreaders

• Intelligent Thermal Management Systems (iTMS)

• k-Core® Annealed Pyrolytic Graphite (APG)

• Liquid cooling systems

• Material development, characterization and testing

• Vapor chambers

Aluminum Vacuum Brazed Cold Plate

MATERIALS TECHNOLOGY SPOTLIGHT

k-Core® Cold PlateAluminum Vacuum

Brazed Chassis