Wyman-Gordon Mountaintop is an industry leader in the production of flash welded and cold-rolled rings and cases for gas turbines. State of the art forming, welding, and sizing equipment are utilized to produce superior quality components which consistently meet or surpass aerospace standards. We supply major engine programs worldwide with near-net-shape rings and cases.
Wyman-Gordon Mountaintop is the only manufacturer of flash welded rings to incorporate full CNC controlled welders. This enables us to offer our customers a level of weld integrity that is unsurpassed in the aerospace industry.
We also produce engine rings and cases using our proprietary Tru-Formâ„¢ manufacturing process. The Tru-Formâ„¢ process utilizes flash welded, seamless rings as starting pre-forms, and employs a unique cold-rolling process to closely follow finished part configurations. The near-net-shape ring technology is accepted throughout the industry. This innovative rolling and forming technique has significantly improved over the years and, coupled with the latest technological advances, provides exceptional savings and value to our customers.
We specialize in small production runs and continually work to reduce lead times so we can be most responsive to changing customer schedules. Our experience with small production runs also allows us to efficiently develop small quantities of prototype parts for engine development applications.
Products
Wyman-Gordon Mountaintop is the leading supplier of flash welded rings for gas turbine applications. Our products provide our customers with reduced material envelope designs, machining time savings, and part to part consistency.
State of the art forming, welding, and sizing technology are used to produce high quality, low cost, near net shape flash welded rings for the following applications:
- Stators
- Flanges
- Nozzle Supports
- Combustor Rings
- Rotating Air Seals
Tru-Formâ„¢
The Tru-Formâ„¢ cold rolling process is a CNC controlled ring rolling process which utilizes flash welded and seamless rings to produce engine cases and structures, including:
- Combustion Chamber Liners
- Combustion Domes
- Combustion Chamber Outer Cases
- Turbine Cases & Supports
- Structural Supports
- Nozzle Supports
- Fan Cases
- Seal Rings
- Bulkheads
Flash Welded Rings
Rings as Bands (Height < Wall)
| I.D. | Face Height | Wall | Maximum Cross Sectional Area |
|---|
| 6" - 11" |
0.5" - 4.0" |
0.25" - 1.0" |
4.0 sq. inches |
| 11" - 18" |
0.5" - 10.0" |
0.25" - 2.0" |
10.0 sq. inches |
| 18" - 75" |
0.5" - 12.0" |
0.25" - 2.5" |
15.0 sq. inches |
Rings as Flanges (Height < Wall)
| I.D. | Face Height | Wall | Maximum Cross Sectional Area |
|---|
| 6" - 11" |
0.25" - 2.0" |
0.5" - 2.0" |
4.0 sq. inches |
| 11" - 18" |
0.25" - 2.0" |
0.5" - 3.0" |
6.0 sq. inches |
| 18" - 30" |
0.25" - 2.5" |
0.5" - 4.0" |
10.0 sq. inches |
| 30" - 60" |
0.5" - 2.5" |
1.0" - 5.0" |
15.0 sq. inches |
| 60" - 75" |
0.5" - 2.5" |
1.0" - 6.0" |
15.0 sq. inches |
Alloys Which May Be Used As Rings
- Iron Base Alloys
- Nickel Base Alloys
- Cobalt Base Alloys
- Titanium Base Alloys
Exceptions - Alloys Which Cannot Be Readily Flash Welded as Rings
- Air hardening iron base alloys such as A2 tool steel, 440 C stainless steel etc.
- Aluminum Alloys
- Copper Alloys
Cost Savings
Flash welded rings offer substantial cost saving advantages as compared to traditional hot rolled seamless forgings. Each part is specifically designed to minimize material input and subsequently reduce costly down-stream machining operations. Parts are routinely designed to allow for a maximum 0.045" to 0.060" machining envelope. State of the art forming and sizing equipment allow for exceptional control of flatness and roundness tolerances, which enables Wyman-Gordon to manufacture the most consistent and highest quality rings in the aerospace industry.
Benefits of Near-Net Shape Flash Welded Rings
- Reduced material input
- Reduced machining operations
- Part to part consistency
- Tightly controlled diameter tolerances
- Large range of sizes and configurations
Tru-Formâ„¢ Rings & Cases
- Super Alloys: Iron Based and Nickel Based
- Stainless Steels
- Alloy Steels
- Proprietary Alloys
Dimensions
- Axial Heights to 30 inches
- Wall thickness 0.030" to 2"
- Wall Thickness Control +/- 0.007
- Diameters 5 inches to 100 inches
- Diameter tolerances +/- 0.30"
- Roundess 0.030"
- Flatness 0.030" as formed, machined 0.002"
Welding Technology
With the introduction of the Tru-Formâ„¢ cold rolling process, improvements in welding technology were required so flash welded rings could withstand rolling pressures in excess of 250 tons and cold sizing in excess of 40%. Extensive welding research was undertaken to incorporate part-specific welding parameters, which optimize the flash welding process. In order to control and repeat these parameters, each welder has been thoroughly upgraded and fitted with the latest CNC controlled welding electronics. These CNC upgrades allow us to offer our customers exceptional weld integrity, which is unparalleled in the aerospace industry.
Quality
Wyman-Gordon Pennsylvania comprises two state of the art manufacturing facilities located in Northeast Pennsylvania. Our facilities are Nadcap-certified for heat treating, flash welding, and metallurgical laboratory. In addition, we are AS9100/ISO 9001:2000 Certified/Registered and ISO 14001 Certified/Registered.
Approvals
Wyman-Gordon Pennsylvania holds quality approvals from the following organizations:
- General Electric
- Pratt & Whitney Aircraft
- Pratt & Whitney Canada
- Honeywell
- MTU
- MHI
- Snecma
- Rolls-Royce
- Solar Land Turbines
- Boeing
