aerospace - mj sections - precision cold forming and ... · rings can include hydraulic stretch...

www.mjsections.co.uk

Precision Formed & Machined

Components for Aerospace

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WHITE SWIRL WITH GLOW 74%.pdf 20/6/12 12:01:44

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


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


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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



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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.


Head OfficeMJ Sections Ltd,

Marriott Road Industrial Estate, Netherton, Dudley, West Midlands, DY2 0JZ

tel: 01384 230444fax: 01384 256964


Halesowen Machining FacilityM.J Sections Ltd,

130 Stourbridge Road, Halesowen, B63 3UN

tel: 01384 230444fax: 01384 256964


Unit 14 Bagley Industrial Park Northfield Road,

Netherton, Dudley, West Midlands. DY2 9DY

tel. 01384 238451fax. 01384 245971

www.electro-discharge.co.uk


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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MJ SECTIONS LOGO HEAVY-LIGHT.pdfPage 1 29/5/15 15:09:27

aerospace - mj sections - precision cold forming and ... · rings can include hydraulic stretch...

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