Morgan Advanced Ceramics, Stourport

Core Technologies/ Capabilities  - Freeze Casting Ceramic Components

An Advanced solution for highly durable, cost-effective cast ceramics

Morgan Advanced Ceramics’ freeze cast process offers for the first time, truly durable cast ceramic components, capable of use in a wide range of high wear applications. For example, in superplastic forming (SPF) tools, composite forming tools, press platen components, or in any process requiring components with improved material properties compared to traditional refractory ceramics, but at a low cost in comparison with metal alternatives. 

Already used by some of the world’s leading SPF and composite material producers, particularly in the Aerospace industry freeze cast ceramic could be the solution to your engineering challenge.

Benefits of freeze cast ceramics:

• Large and complex geometries available:
  Products can be supplied in sizes of greater than 1.5m x 1.5m. For still larger requirements, flush-fitting sectioned tools can be produced. Complex working surface geometries can be achieved without need for secondary processing.

• Precision:
  Because components are made by the Freeze Casting process are near net shape after firing, the system offers excellent precision, particularly for components which are to be used in conjunction with other parts or as forms. This removes the need for extensive machining after casting.

• Freeze cast ceramics have excellent thermal stability:
  Because it is a fully fired ceramic (fired to 1200°C) the components remain flat and distortion free with extended use. Unlike many other ceramic materials based upon castable alumina, the ceramic used here has graded properties, which makes it an ideal candidate material for super plastic forming tooling

• Low mass:
  Freeze cast ceramic is 40% the density of high temperature steels.

• Hardness:
  The working surface of the ceramic is a composite of Chrome Oxide and Aluminium Oxide and hardness can be developed as high as 40 on the Rockwell C Scale 

Materials

Freeze cast products are commonly required in either Alumina (ideal for tooling dies and those products requiring an extremely hard working surface) or Fused Silica, for applications in which thermal expansion must be almost zero. 
Data sheets are available as PDF downloads by clicking here. Alternatively contact our Sales and Applications team for further information.

Core Technologies:

• Dry Pressing

• Ceramic Injection Moulding

• Iso-static pressing

• Extrusion

• Intermittent and Continuous Kilns

• Diamond Grinding

• Lapping and Polishing

• Freeze Casting Ceramic Components

• Silicon Nitride for highly demanding thermal and wear applications