Advanced Solutions
for Automotive
Applications
AUTOMOTIVE
Morgan Advanced Materials
Morgan Advanced Materials is a global materials engineering company which designs and
manufactures a wide range of high specification products with extraordinary properties, across multiple
sectors and geographies.
From an extensive range of advanced materials we produce components, assemblies and systems that
deliver significantly enhanced performance for our customers’ products and processes. Our engineered
solutions are produced to very high tolerances and many are designed for use in extreme environments.
The Company thrives on breakthrough innovation. Our materials scientists and applications engineers
work in close collaboration with customers to create outstanding, highly differentiated products that
perform more efficiently, more reliably and for longer.
Morgan Advanced Materials has a global presence with more than 9,000 employees across 50 countries
serving specialist markets in the energy, transport, healthcare, electronics, security and defence,
petrochemical and industrial sectors. It is listed on the London Stock Exchange in the engineering sector
(ticker MGAM).
About our Automotive business
Morgan provides the global automotive sector with a wide range of components that are used in
modern cars and to aid vehicle manufacturing. Harnessing our world-class design expertise and
specialist manufacturing capabilities, we work in partnership with some of the world’s largest tier-one
automotive suppliers, developing competitive tailored solutions to meet the increasingly challenging
demands of the sector. We are at the forefront of technology helping manufacturers improve vehicle
safety, performance, energy efficiency and comfort to create more fuel efficient, safer vehicles.
Key benefits
Proven technologies in demanding automotive applications
Investors in advanced materials innovation - helping you get the best materials
Broad array of products - enabling us to deliver optimised solutions
Expert application engineering support
Global footprint - providing you with support locally, when you need it
AUTOMOTIVE
Improving
the safety,
reliability and
performance
of modern
vehicles
Thermal management solutions
Our market leading Kaowool®, Superwool® and Porextherm WDS™ high temperature insulating advanced material solutions are used for
thermal management, heat shields and noise reduction in automotive exhaust systems, air bag filtration and brake pad applications.
Custom engineered heat shields from Morgan are comprised of a metal faced exterior with an interior layer of our high temperature insulation
products such as blanket, paper, or microporous materials. Heat shield design assistance is available for heat management around the fuel line
and fuel tank, electronics, and other heat sensitive components.
Insulating fibres
For over 30 years Morgan has delivered ceramic fibre based materials for the automotive industry. We manufacture ceramic fibres in a range
of chemistries tailored to the demands of the specific application. Through secondary processes, the fibers are then made into a range of
formats including:
• Papers
• Felts
• Blankets
• Vacuum formed shapes
• Coatings and adhesives
These materials give automotive engineers and designers the tools to solve thermal management challenges that arise in both OE and aftermarket
applications such as; heat and NVH shields, friction modifiers, filtration and gaskets.
Micropourous thermal
management solutions
The properties of our microporous insulation make
it the ideal solution for the most demanding, high
temperature environments. Our WDS™ insulation
range, which features temperature stability up
to 1100°C, provides a superior material for use
within the automotive sector, particularly for heat
protection of exhaust systems. WDS thermal
protection also offers weight and space savings to
customers, making it the optimum material for this
application
Key Benefits of WDS™
• 4-5 times better insulation than conventional products
for exhaust systems
• Reduces surface temperature dramatically
• Reduces the insulation thicknesses and thus the thickness and/
or size of the construction
• High pressure resistance
• Significant thickness weight savings
• Vibration resistant WHEN SEALED AND INSTALLED WITHIN
A TIGHT CASING
• Reduces part variety as no heat shield necessary
3
AUTOMOTIVE
Automotive heat shields
Our heat shields are produced by a highly experienced design, testing
and manufacturing team that provide high performance products, machined to tight tolerances.
We have a proven track record working with some of the world’s largest automotive
companies for both the production vehicle and motorsport markets.
Our automated production line enables us to produce
over 600,000 shells per year.
Automotive applications commonly utilise heat shields made with a
thin stainless steel or inconel shell ranging in thickness from 0.1mm to
0.15mm that encapsulates Superwool® PlusTM insulating fibre, silica fibre
or WDS™ micropourous insulation material.
Key Properties
Typical Applications
• REDUCED Thickness
• Exhaust Tunnel Insulation
• Lightweight
• Turbo Charger Insulation
• High Reactivity
• Exhaust Manifold Insulation
• High Resistivity
• catalytic converter and particle
• Low THERMAL ConductivitY
filter insulations
Superwool® EnfilTM fibres
Many of the worlds largest brake pad manufacturers utilise the characteristics of our Superwool® Enfil™ fibres, in both OEM and aftermarket
formulations, to significantly increase brake friction pad stability and improve fade and recovery characteristics without sacrificing rotor wear or
pad weight loss.
Our fibres provide an alternative to semi-metallic pads and address formulator concerns for high temperature fade, rotor wear, wheel dust, and
NVH. Superwool insulating fibres are not classified carcinogenic by IARC or under any national regulations globally. They have no requirement
for warning labels under GHS (Globally Harmonised System for the classification and labelling of chemicals).
In Europe, Superwool® fibre meets the requirements specified under NOTA Q of European Directive 67/548. All Superwool® fibre products
are therefore exonerated from the classification and labelling regulation in Europe.
Key Features
• Suitable for continuous use at 1024°C (2200°F)
• Significantly increase brake friction pad stability
• Improved fade and recovery characteristics
• Patented technology
• Global sourcing
• Extensive R&D
4
Pump and Valve Components
Morgan has a proven track record in supplying resilient, high-performance and cutting edge solutions to automotive manufacturers.
We are perfectly placed to support the demanding needs and requirements in the sector with global manufacturing and supply
capabilities in various volumes. We can design and manufacture custom components to meet specific requirements. Our components
are up to 60% lighter than steel, this weight saving contributes to increased energy efficiency.
Bearing for Exhaust Gas Recirculation (EGR)
The ability of our radial bearings to lubricate at the high temperatures engines must run
at enables them to provide an excellent solution for regulating exhaust gas recirculation
resulting in more efficient engine systems. Our innovative materials also reduce nitrogen
oxides by lowing combustion temperatures in the combustion chamber.
Brake booster
We provide a selection of high performance vanes and rotors manufactured from our
specialist formulations of carbon / graphite materials which feature superior tribological and
wear characteristics. Chemically inert and dimensionally stable they are ideally suited to
automotive applications such as brake boosters.
Electric / hybrid vechicles: sealless cooling pump bearing
Advances in battery technology are leading to the need for increasing demanding thermal
management solutions. The exceptional properties ceramic and carbon offer provide
electric and hybrid vehicles with the pump technology needed to circulate aggressive
coolant through the Lithium-Ion batteries. The reduced weight contributes to low noise
whilst running and increased energy efficiency of the vehicle.
Fuel pump bearings
Radial bearings developed from our leading carbon material make the use of ethanolcontaining fuel blends possible by providing improved lubricity in high pressure fuel pump
environments.
Electronic leveling valves
Air suspension, and its contribution to improve driving comfort, is particularly well-established
as a valuable feature in heavy vehicles. Morgan produces high purity alumina slider valves to
a very high flatness tolerance enabling the creation of the air tight seal required for Electronic
Leveling Modules (ELM). The exceptional hardness offered by ceramic increases reliability
throughout the product life cycle.
Components for electric vacuum pumps
Morgan’s products increase braking safety and operation convenience via a vacuum supply to the brake booster, exhaust gas recirculation valve
and turbocharger used for diesel and gasoline engines.
Thermal management
Morgan’s Engine-Driven Water Pump Seal is favoured by automotive water pump manufactures who choose an alumina ceramic/ carbon seal
assembly due to the materials high wear and corrosion resistance to the circulation of aggressive anti-freeze and coolant solutions.
AUTOMOTIVE
Piezoelectric ceramic components
As the automotive industry continues to advance, smarter cars are being developed as a result. Our piezoelectric components
are ideal for the increasing number of sensing applications being incorporated into vehicles
Piezo-ceramic discs used in parking sensors
Morgan produces over one million piezo-ceramic discs used for proximity sensing in car
parking sensors annually, we also have the capability to make complete sensor assemblies
to meet specific requirements.
Wheel balancing transducers
Morgan manufactures sensors for dynamic force measurement, our standard sensor is
widely used by the automotive industry in wheel balancing equipment. It cans also be
used in other applications including measuring the force exerted on the brake pedal during
brake tests. The sensor is supplied moulded with a range of lead and connector options
available.
Engine knock sensors
Using feedback from the vibration inside the engine, Morgan Advanced Material’s
manufactures custom sensors to detect this early to avoid catastrophic damage.
Ultrasonic Fuel Flow Sensor
Morgan’s ultrasonic sensors have many other applications, including being used as fuel flow
sensors. They provide highly accurate measurement in a challenging environments and
are primarily used within the motorsport industry to promote efficiency by limiting peak
engine power.
Fuel Level Sensor
Morgan provide a highly accurate fuel level sensor, designed to thrive in harsh environments
the corrosion resistant assembly allows for highly accurate fuel monitoring.
Multilayer Actuators
Morgan’s superior piezo bimorph actuators are customised to suit requirements within automotive applications such as photonic optical switching.
They provide large displacement and force at low voltage, relative to monolithic PZT.
Occupant safety systems
Morgan’s ultrasonic sensors can be used as personnel detection systems, enabling automotive manufacturers to ensure that the airbags are
deployed in the safest possible manner according to the passenger’s position.
Adblue / DEF Sensor
Used to check quality and level of diesel exhaust fluid, commonly known as adblue, Morgan’s ultrasonic sensors, when combined with electronics,
use speed of sound and density measurements to ensure top quality fluid.
Automotive manufacturing applications
Rotary® Transfer Systems used in vehicle manufacturing
Under our Refoka brand we supply advanced hybrid technologies for welding turntables and
trunnions used in automotive body shops. Incorporating key features such as; maintenance free
optical fibre for data signals up to 1 Gbit/s, module slip rings for power transmission and rotary
joints for continuous rotating transmission of air and fluids i.e. water, oil and glue. Especially for data
signals we deliver internal repeaters with connector RJ45 or SCRJ, to see the slip ring as an
own device in customer´s system. Our slip rings are helping improve reliability and reduce
equipment downtime resulting in better manufacturing efficiency. Rekofa is a trusted name in the
sector with over 35 global OEM using our systems for over 30 years.
Additionally, our slip rings used in robotic gluing and handling applications enable the endless
rotation of the 6th axle and are widely used by some of the world’s biggest names in vehicle
manufacturing.
Electrostatic paint spraying
Our high voltage capacitors and voltage multiplier assemblies can be found
in the latest electrostatic paint spraying processes helping improve the speed
and finish achievable by paint spraying machines and operators.
Thermal management papers
for windscreen manufacture
Our Superwool® papers made from low-biopersistence high-temperature
fibres are placed on both sides of the glass to protect the windscreen from
physical damage in the glass bending process, while allowing sufficient heat
transfer. Enabling more efficent manufacuting with less waste and a higher
quality finished product.
Cerox® fired refractory shapes
Morgan produces a range of Cerox® fired refractory shapes, available in
various material compositions, including many specifically used for the
manufacture of automotive turbochargers. Our Cerox shapes are fired to
temperatures that create especially strong molecular bonds, making them
superior in applications required to produce clean and contaminant-free
metals. They offer resistance to chemical attack from acids, slags, and gases
to produce the cleaner, contaminant-free metal demanded by automotive
steel foundries.
AUTOMOTIVE
Certech® Ceramic Cores
Our ceramic cores offer high performance stability, even at high temperatures, helping
manufacturers of castings for vehicle engine components to reduce scrap, improve
productivity whilst also improving the quality and surface finish of components
produced. We also manufacture wax injection moulded cores, porous ceramics for
automotive such as fuel pumps.
With our wide range of silica and silica zircon materials and our proven technical
expertise, we are able to custom design cores suitable for a wide range of
automotive casting applications.
Our cores are also suitable for the casting of automotive cylinder heads, offering
benefits such as improved heat management of the engine when in service owing
to improved surface finish around the cylinders and possibility to reduce cast sections
on new deigns as thinner sections can be achieved by using ceramic compared to
sand cores.
Nilcra™ ceramic weld pins for projection welding
The automobile industry is a demanding environment, requiring the best practices and
materials. Great emphasis is placed on precision and cost. Nilcra Zirconia™ ceramic is perfectly
suited to match these challenges.
Our advanced Nilcra Zirconia ceramic is the idea choice for the for the projection welding industry. The unique combination of
toughness and durability has ensured that Nilcra has replaced both conventional coated pins and other weaker ceramics.
As a result of Nilcra’s extraordinary toughness, our weld pins greatly reduce unplanned down time and increase performance, whilst
improving product quality.
Key benefits
• Extreme wear resistance and durability
• High surface finish
• Electrically insulating
• Resistance to welding sparks and spatter
• Non-magnetic
• Excellent service life
Carbon Brush
Morgan is a world leader in the design and manufacture of high quality
carbon brushes for improved machine reliability. We offer a wide range
of high performance brushes for the automotive industry to extended
operational life and optimum motor performance for our customers.
Premium Crucibles for component casting applications
Our Syncarb Z2 e2 premium quality hybrid ceramic bonded clay graphite crucible, with a high
silicon carbide and graphite content is used by some of the world’s leading engine and parts
manufacturers. The Syncarb range performs exceptionally well in the melting and holding of
aluminium and other low temperature alloys in gas and electric resistance furnaces, making
it ideally suited to automotive applications. Superior thermal conductivity, high mechanical
strength, erosion resistance and good shock resistance
AUTOMOTIVE
Products used during manufacture
Wheel Balancing Transducers
Our wheel balancing transducers are widely used in testing and
maintenance applications helping ensure wheels are correctly balanced.
9
1
Heat shields
Adblue / DEF sensor
Our stainless steel encapsulated Heat shields provide
a lightweight custom shaped solution, incorporating
our Superwool® and Kaowool® fibres or microporous
WDS® Flexible Contour for insulating key areas and
providing noise reduction.
Morgan’s ultrasonic sensors can be combined
with electronics to check quality and level of diesel
exhaust fluid, commonly known as Adblue using
speed of sound and density measurements to ensure
top quality fluid.
10
Products used in vehicles
Occupant safety system sensors
Morgan’s ultrasonic sensors are used in personnel detection
systems, enabling automotive manufactures to ensure that
the airbags are deployed in the safest possible manner
according to the passenger’s position and meet stringent
safety requirements.
Windscreen manufacturing process
Our low-biopersistant Superwool papers allow heat transfer during the
glass bending process and protect against physical damage.
2
Certech Ceramic Cores
®
Our ceramic cores are used in the casting of automotive engine
components and cylinder heads. They offer high performance stability,
helping manufacturers reduce scrap, improve productivity and improve
the overall finish.
16
3
Electrostatic paint spraying
Our high voltage capacitors and voltage multiplier assemblies can
be found in the latest electrostatic paint spraying processes helping
improve the speed and finish achievable by paint spraying machines and
operators.
Fuel Pump manufacture
Morgan manufactures wax injection moulded cores and porous ceramics
used in fuel pump manufacturing applications.
4
5
5
2
10
7
15
6
4
8
1
17
18
1
6
7
9
4
14
10
Our piezo-electric ceramics are used for proximity parking
sensors commonly found in vehicle bumpers, helping
improve driver awareness and safety.
12
8
Designed to thrive in harsh environments, the corrosion
resistant assembly of our fuel level sensor allows for accurate
fluid monitoring
8
Engine knock sensors
Using feedback from the vibration inside the engine, Morgan’s
ceramic is used within knock sensors to detect vibrations
early and avoid catastrophic damage.
1
3
6
Our Superwool Enfil Fibres are used within brake pads to
significantly increase brake friction pad stability and improve
fade and recovery characteristics without sacrificing rotor
wear or pad weight loss.
Alternator
9
DC motor
14
Starter motor
10
ABS motor
15
The properties of our carbon and ceramic materials are
enabling the pump technology needed in electric and hybrid
vehicles to circulate aggressive coolant through the LithiumIon batteries, whilst also providing weight saving benefits.
HCF
11
Fuel / oil pump
16
Carbon/bearings vanes and rotors
Radiator coolong pump
12
Wiper motor
17
EVP rotar and vane
13
HVAC motor
18
12
5
Our Seals and Bearings business also produces carbon/
graphite vanes and rotors offer outstanding thermal and
chemical resistance properties along with superb wear
resistance. Applications include; Fuel Pumps, Water Pumps
(Cooling/Heating), EGR Valves and Electric Vacuum Pumps.
Our insulating Superwool® and Kaowool® fibres
or WDS® microporous solutions are used for heat
shields in the engine compartment.
Battery cell insulation for hybrid vehicles
Superwool® insulating fibers or WDS® microporous are
used as non-combustible thermal barriers for battery
cells in electric vehicles.
13
6
Vehicle cooling pump seals
Engine compartment insulation
11
4
Brake pads
8
8
3
Fuel level sensor
11
13
2
Parking sensors
9
Fuel tank protection
Our heat shields are ideal for use in fuel tank protection. With a proven
track record working with some of the world’s largest automotive
companies to provide high performance products,we can produce
solutions to tight tolerances, in high volumes.
2
7
Automated vehicle production equipment
Our Rekofa branded slip rings are used in continuously rotating robotic
arms for gluing and handing processes. Our Rotary Transfer systems
enable maintenance free optical fibre data signals for power transmission
and rotary joints.
Providing highly accurate measurement in a challenging
environments, Morgan’s ultrasonic fuel flow sensors are
primarily used within the motorsport industry as they promote
efficiency by limiting peak engine power.
5
3
Welding of car components
Ceramic weld pins manufactured from Morgan’s Nilcra™ zirconia offer
significantly increased performance and service life, resulting in reduced
process downtime and provide associated cost savings.
Ultrasonic fuel flow sensor
14
Muffler Insulation
WDSR microporous and Superwool and Kaowool
insulating fibers often used for exhaust insulation due to its
thermal management and noise reduction properties.
®
®
®
Airbag filter assemblies
Our thermally insulating papers and microporous solutions provide
an excellent medium for filtration in airbag filter assemblies.
7
8
Alumina shafts
Our Alumina Shafts offer a combination of good
mechanical and electrical properties, combined with a
high compressive strength and dimensional stability across
very wide temperatures; making them ideal for automotive
applications.
9
AUTOMOTIVE
From parking
sensors and Engine
Management
Systems to Exhaust
Filtration Systems,
our components
are used on vehicles
around the worlD
where performance
matters
BU
NO
EM
SS
ME
AS
UI T
O TNI A
VE
M O R G A N A D V A N C E D M AT E R I A L S
LISTED ON
THE LONDON
STOCK
EXCHANGE
OVER
9000
SELLING INTO
>100
EMPLOYEES
COUNTRIES
MANUFACTURING IN
>30
COUNTRIES
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all enquiries,please
please contact
ourour
specialist
sales and
manufacturing
sites:
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contact
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sales
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sites:
Europe
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Morgan
Advanced Materials
Morgan Drive
Morgan
Drive
Stourport-on-Severn
Stourport-on-Severn
Worcestershire DY13 8DW
Worcestershire
DY13 8DW
United Kingdom
United Kingdom
Morgan Advanced Materials
4000 Westchase Boulevard
4000
Westchase
Boulevard
Suite
170
Suite
170,
Raleigh,
Raleigh, NC 27607-3970
NCUSA
27607-3970
USA
Morgan
Advanced Materials
Avenida do Taboão 3265- São
Avenida
Bernardodo
doTaboão
Campo3265- SP São
Bernardo
do
Campo
– SP
CEP 09656 000
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000
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Morgan Advanced Materials
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Morgan Advanced Materials
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