Materials Research Laboratory
Unmatched among copper alloy producers in the Americas, and a leader in related materials technology the world over, Olin Brass Materials Research Laboratories (MRL) is staffed with a team of experienced metallurgists, engineers and materials researchers focused on new product and process enhancement activities. Since the 1950’s MRL has excelled at quickly translating ingenious ideas into commercially successful alloys, products and processes.
With pilot plants, testing labs and other developmental technologies, coupled with a team of professionals, MRL is dedicated to getting the job done. MRL helped build Olin Brass into the biggest and best brass business in North America and one of the most innovative suppliers of high-performance electronic materials and packaging solutions.
Casting Development
Since pioneering the introduction of direct chill semi-continuous casting in the U.S.A., MRL has been providing casting expertise for 40 years in the nonferrous field. Working closely with commercial casting plants, we have developed unique procedures and equipment for alloying, controlling scrap remelting to maximize recovery, and filtering alloy melts to minimize inclusions. Melting and casting procedures have been tailored to improve cast bar quality and yield in commercial operations. Special technologies have been developed to reduce costs and provide near net-shape benefits.
Alloy Development
Olin Brass and MRL are the world's leaders in copper alloy development. We have excelled at developing alloys that match properties to end product performance requirements. By working closely with our factories to produce material that performs consistently during part fabrication and while in-service, we play a vital role in helping our customers successfully commercialize their technologically advanced products.
Electrochemical Processing
Electrochemical surface modifications further enhance the technical attributes of foil products. Developments made by scientists on a laboratory scale at MRL are scaled up to production facilities within Olin Brass and licensed to users around the globe. A2 Treatment and Copperbond™ surface adhesion enhancements are just two examples of products developed by MRL to solve customer challenges. Most recent requirements for even thinner foil have been met by the development of Copperbond™ XTF; a peelable foil allowing electronics designers to work with copper layers down to 1 micron in thickness. Specialized testing related to foils and a high resolution FESEM augment the expertise to develop and support these products.
Electrical Interconnects
MRL has contact physics and materials experience to conduct studies in metal connector and contact systems for automotive, electrical and electronic applications. A systems approach is used to develop cost-effective coating, barrier layer and substrate materials for varied operating environments. The technical approach utilizes lab tests to simulate service conditions for screening candidate coating and substrate systems in order to reduce development cycle time. A fully automated, computer driven, data acquisition and control system is used to measure static contact resistance, fretting wear, macrowear and coefficient of friction. The equipment simulates and quantifies various failure mechanisms typically responsible for connector malfunction.
Test Development
MRL has the capability to perform a very wide range of tests to applicable standards (ASTM, MIL, SEMI, USCAR, IPC) or in accordance with locally developed or customer specific procedures. If a currently available test is not appropriate, a new test can be developed. The development of a variety of specialized tests to characterize both materials properties and component performance is a strength of MRL. These tests simulate conditions relevant to commercial applications.
Materials Characterization
A broad range of Material Characterization capabilities are available to support the MRL Technology databases. Test/characterization systems include:
- Metal Forming
- Mechanical Testing
- Surface Related Measurement
- Corrosion / Oxidation Testing
- Microstructural / Metallographic
- SEM EDS / X-RAY Diffraction
- Bulk Property Measurement Tests
- Chemical Analysis (Optical Emission and ICP)
- Analytical electron microscopy (STEM, TEM)