Morgan develops powerful ceramic-to-ceramic bonding technique

Using a preparatory formulation applied to one or both faces of the parts to be joined, the bonding technique delivers high tensile strength. The process is suitable for bonding both porous and fully dense ceramics, making it ideal for a variety of applications from fluid handling systems to diode pump lasers.

Internal testing of the new bonding technology has delivered impressive results, with a bond strength of 13 MPa and a force to failure of 11,330kgf. Both of these figures represent a level of performance many times that of co-firing (7.7MPa and 577.97kgf in the same application) and adhesive bonding (5.4MPa and 460.33kgf).

Internal pressure tests have shown that the joint can withstand pressures in excess of 25bar (design dependent). Tightly controlled tolerances and clearances allow Morgan’s engineers to design systems in which a captivated rotor using this bonding technology can operate in a high-pressure environment.

Such design features and technology open new opportunities for applications where pressure differential principles are applied, such as desalination.

In another development, the company has produced 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.