The Certech business of Morgan Technical Ceramics (MTC), offers high-quality ceramic cores for the production of industrial gas turbine (IGT) blades. MTC is a leading manufacturer of innovative ceramic, glass, metal and engineered coating solutions.
Within the industrial gas turbine industry, ceramic has emerged as the material of choice for a variety of reasons. Ceramic is capable of producing thin cross sections and holding tight tolerances which help produce accurate internal passageways in aerofoil and IGT castings. It is also strong enough to withstand the wax injection step used in the investment casting process. While the casting is being poured, the ceramic core remains stable, yet is readily leached using standard foundry practices once the casting has cooled.
The proprietary injection molding process used to create MTC Certech ceramic cores is superior to other core manufacturing techniques because it is much faster than competitive processes, allowing high volumes of cores to be manufactured in less time. Additionally, the ceramic material utilized by MTC Certech to make the cores has the added benefit of being less abrasive on the injection molds that are used, thereby increasing their lifespan. This translates to over 100,000 shipped cores per cavity, the most per cavity in the industry.
The result is a ceramic core that exhibits greater dimensional accuracy while maintaining tight tolerances without distortion. Additionally, MTC Certech cores remain stable at higher temperatures and do not prematurely deform. This is an important consideration given the extremely high temperatures required for IGT component production. Further, MTC Certech’s cores can be completely dissolved chemically after the casting has cooled, leaving the clean air passage replica needed in today’s efficient turbine engines.
As part of MTC Certech’s injection molding technique, a thermo-plastic material is melted and mixed with ceramic powder. As the mixture cools, the casting is set, without abrasive wear and tear on the die, allowing more parts to be produced from a single die.