LATEST2 EPSRC PROGRAMME

GRANT:

LIGHT ALLOYS TOWARD

ENVIRONMENTALLY

SUSTAINABLE TRANSPORT

www.manchester.ac.uk/latest2

Professor George E. Thompson: Principal Investigator

EPSRC Programme Grant LATEST2

Light Alloys Towards Environmentally Sustainable Transport: 2nd Generation Solutions for Advanced Metallic

Systems

Award of £5.7 M over 5.5 years (10 July, 2010 to 9 January, 2016)

Significant collaboration highlighted and leverage funding anticipated from a wide range of partners (industry,

academia and research organisations)

Metallurgy Materials Engineering Chemistry Chemical Engineering Electrochemistry Physics

LATEST2 - Integrated Interdisciplinary Team

Principal and Co-Investigators:

8 Manchester staff members, including 4 Professors, 2 Readers, 1 Senior Lecturer & 1 LATEST2 Fellow (internationally recognised in their fields) plus associated academic staff from the School together with national and international collaborations

Expertise: Alloy Design Deformation Forming Joining Surface Engineering Corrosion Control and Corrosion Protection Performance

Team completed with a Programme Manager, Outreach Officer and Administrative Assistant, and Technical support

Materials Activities in the School and Faculty

The Materials Performance Centre (2002) The Northwest Composites Centre (2005) The Manchester X-ray Imaging Facility (2009) The Stress and Damage Characterisation Unit (2000)

Cross School Activities University of Manchester Aerospace Institute (UMARI) (Framework Agreement with Airbus completed in 2012) Rolls-Royce Nuclear University Technology Centre Nuclear Advanced Manufacturing Centre EPSRC Programme Grant (NUMAN) Diamond Light Source BP Corrosion Laboratory plus chair position, & BP ICAM (International Centre for Advanced Materials) Hub AkzoNobel Collaboration, plus AkzoNobel Laboratory and chair position established at Manchester National Graphene Institute Multidisciplinary Characterisation Facility

LATEST2–Vision/Research Theme Support dramatic reductions in the environmental impact oftransport by facilitating a step change in high-performance light alloy design solutions in the automotive and aerospace industries. RoCO2 emissions => 95 g/km by 2020;

Address the key materials engineering issues and technologies required to enable introduction of a second generation of increased performance light alloy materials in more mass efficient products, utilising multi-material structures, and more complex components. architectures

Vehicle transport roadmap: CO2 emissions to be reduced to 95 g/km by 2020 and then from 20% to 80% below 1990 levels by 2050; aviation, 50% of 2005 levels by

2020

Challenges,Themes and Theme Interactions

Theme 1: Conquering Low Formability Forming high performance light alloys andtailored panels Advanced forming processes and methods (graded materials) Modelling micromechanics of deformation,forming limits and surface finish

Theme 2: Joining Advanced Alloys and Dissimilar Materials Joining multi-material, high performance light alloy structures Joining dissimilar material combinations Modelling interface reactions, weld microstructures and performance

Theme 3: Surface Engineering for Low Environmental Impact Corrosion mechanisms at all length scales In-service protection and cosmetic corrosion control Surface engineering for adhesion/joint performance(e.g. composite to metal bonding)

Simulation, Modelling and Recyclability

Output and Technology TransferEnabling knowledge for manufacturing advanced light alloy materials and their interfacing

in multi-material systems, with more complex, mass efficient, design architectures

TWI Surfi-Sculpt TWI Surfi-Sculpt

EC - Superlight Car Project (SCP): 37% Weight Saving

Aluminium

Steel MagnesiumPlastic Carry-

over

Further requirements: Increased performance light alloys integrated in multi-material designs

Reduced energy, environmentally-compliant manufacturing processes

Increased use of recycled materials, greater service life, enhanced functionality

Accelerated time to market, enhanced modelling and simulation tools

LATEST2- Multi-Material Design

Lesemann, Brockerhoff & Urban, AZTautotechnology, 8,16-20 (2008)

Berger, Lesemann & Sahr, 7th European LS-DYNA Conf (2009)

Joining and corrosion protection are challenges for multimaterial car body design (Dilthey & Stein, Sci. & Tech. of Welding and Joining, 11, 135-142 (2006))

ALIGNMENT WITH EPSRC STRATEGYEPSRC HAS THREE CLEAR GOALS OF (i) SHAPING

CAPABILITY, (ii) DEVELOPING LEADERS & (iii) DELIVERING IMPACT (SPONSOR NOT FUNDER!)

EPSRC is at the heart of discovery and innovation; its research saves lives, creates prosperity, protects the environment and inspires future generations.

EPSRC is pioneering research and skills for the future.

The research ranges from physics, chemistry and mathematics to materials computing, engineering and high value manufacturing

•CAPABILITY

• IMPACT

• SKILLS

• RESEARCH LEADERSHIP

• PARTNERSHIP

• CREATIVITY

• FUTURE CHALLENGES

• FOCUS

• EXCELLENCE

Global, Economic and Societal Challenge Themes, including:

• Manufacturing the Future-EPSRC• Energy-RCUK Cross Council Theme (low carbon innovation group)• Increased collaboration through Doctoral Training (Advanced Metallics Systems with Sheffield)

Processing and Formability: Theme 1

• Rolling mill; 250 mm rolls for hot and cold rolling• ECAE press and SPF press• Plane strain compression rig• Erichsen 145-60 sheet forming press with image

correlation strain measurement• Full range of torsion/tension/compression testing

over large range of temperatures• In-situ deformation and heating - SEM

Material Characterisation Facilities:

  SEM/EBSD coupled with FIB,  XRD and X-ray microtomography

LATEST2 Research Facilities

Joining: Theme 2

• 25 kW friction stir welding• Friction stir spot welding• Ultrasonic spot welding (Sonobond)• Weld process instrumentation – e.g. thermal imaging• Weld simulators (EMT/Gleeble)• Range of modelling tools, developed in-house and commercial (e.g. THERMOCALC)

Material Characterisation FacilitiesAdvanced microstructural analysis (dual beam FIB, FEG-TEM,

FEG-SEM EBSD etc)

LATEST2 Research Facilities

  LATEST2 Research Facilities Surface Engineering: Theme 3

• Surface analysis/elemental depth profiling (XPS/GDOES) • Electron probe microanalysis (Earth, Atmospheric & Environmental

Sciences)• Image assisted electrochemical probing (ENA), accelerated testing (salt spray / humidity chambers) • Magnetron sputtering for model alloy generation / coating development • SPM/SKPFM probing • Waveform generators for coating by plasma electrolytic oxidation • High resolution, low kV, backscattered scanning electron microscopy /

ESEM aligned to X-ray tomography/ electron tomography (in-situ serial sectioning)

• Laser surface processing (80 W/2 kW KrF Excimer Slab Rofin CO2 lasers)• Total and diffuse reflectance• Local electrochemistry, including SVET

Advanced microstructural analysisDual beam FIB, FEG-TEM, FEG-SEM EBSD etc)

 

Research Facilities/Collaborative Activities In-situ loading experiments using neutron and synchrotron X-ray diffraction and diffraction contrast tomography (ESRF, ISIS); other synchrotron sources plus UK Diamond facility HZG in-situ microstructural analysis of FSW - on FlexiStir Heriot Watt CIM on Laser-based Production Processes University of Kaiserslautern – USW of Al-Ti Cranfield on ALM and dissimilar joining Cambridge University Engineering on process modelling Beijing Institute of Aeronautical Materials/CSIRO – cold spray coatings University of Paris, Jussieu- Van de Graaf Generator, Nuclear Reaction

Analysis, Rutherford Backscattering Spectroscopy Brunel University- Liquid Metal Engineering Loughborough University-Hybrid Machining and Turning Dimokritos (Greece)- Nanocontainers(including Inhibitor-filled containers) FEI- Real Time Electron Microscopy with Brookhaven National Laboratory Daresbury-SuperStem (Liverpool) University of Huddersfield-MEIS and metrology Poeton-industrial scale-up of anodizing processes/ Goodrich-fatigue University of Swansea- local electrochemistry, e.g. Kelvin probe and

scanning vibrating electrode studies Manchester laser surface finishing facilities

Corrosion monitorin

g & protection

of dissimilar

joints

Forming & Micromechanic

s

Surface Engineering &

Corrosion

JoiningAdditive

Manufacturing

Appearance,Near-surface

deformed layers,

Environmental degradation

Composite / metal joints

High strength aluminium

alloys Surface engineering for adhesive

bonding

Tailored Panels

Analytical Techniques

Theme Interactions (multi-disciplinary approach)

2D imaging

3D Tomography

Sub - nmnmμmmmXradia

MicroCTFIB/SEM3View

XUM

SEM Environment

al stages

NikonCT

X-ray Nano-

tomography

Raman

LightMicroscop

y

TEM / STEM

tomography

X-ray Environment

al stages

TEM Environment

al Stages

TEM / SEM Tomograp

hy3Vie

w

SEM Imaging

with EDS and EBSD

X-Ray

Tomography

FIB

3D EBSD

TEM/Atom probe

Scope of Characterisation

Modelling of laser welding Airbus-Wing of the Future Metallics Programme Deformation of CPH Materials Laser Enhanced Manufacturing EADS -TRL Upgrade BAE Systems- Land Systems BP Aerospace- ConsultationTARF-LCV HITEA-TSB Constellium AVIC China ONR, USA SAPA Extrusions BP- Self Healing Coatings Airbus Case Award

Further discussion and consultation:

(i)Akzo Nobel, (ii) BAE SYSTEMS- Wing of the Future, Carbon Allotropes, (iii) Fokker- Consultation- anodizing, (iv) Naples/Alenia, cold spray, smart coatings and anodizing, (v) GATAN/FEI, high resolution tomography and 3D imaging, (v) CSIRO Australia, (vi) TWI, (vi) Academia in Colombia & Chile, (vii) Brunel

LATEST2-Progression/Sustainability

3 Interdisciplinary Research Themes

23 research topics with 3 new topics introduced from the start of the research programme

140 research projects

21 research projects directly funded and 119 added value

72 completed research projects

LATEST2-Research Programme Overview

Administrative Team

Project Manager, Outreach Administrator, Programme Administrative Assistant, 50% directly funded, 50% added value

Technical Team

7 technicians, 2 directly funded, 5 added value

Research Team 1 PI, 6 Co-Investigators, 2 associated Co-Investigators

2 Research Fellows, 1 directly funded, 1 added value12 PostDoc RA, 6 directly funded, 6 added value50 PhD Studentships, 8 directly funded, 42 added value12 CDT PhD Studentships, 4 directly funded, 8 added value29 MSc Studentships added value 4 EngD Studentships added value 8 MEng Studentships added value25 Visiting Scientists added value 2 Research Assistants

Note: Scientific visitors contribute short term project work ranging from 1 – 6 months.

LATEST2-Resource Overview

LATEST2: Prizes and Awards to Researchers,

and Publications (Impact )2012: IOM3 Grunfeld Memorial Award and Prize (J. Robson)

2012: IOM3 Colin Humphreys Education Award (A. Laferrere (& J. Smith))

2013: IOM3 Grunfeld Memorial Award and Prize (M. Preuss)

2012: First Prize in poster contest at 15th Conference on Corrosion and Corrosion Protection of Metals, Czech Republic, (A. Nemcova,P. Skeldon & G. E. Thompson)

2013: Jim Kape Memorial award of the Institute of Materials Finishing for most significat aluminium based paper published in Trans. I. M. F. (M. Curioni, P. Skeldon & G. E. Thompson)

209 publications from 2010 to August, 2013 in prestigious, international journals with academic and industrial collaborators as appropriate

Organised a wide range of outreach activities to communicatethe work of LATEST2, EPSRC and Engineering & Physical Sciences

• Target audiences include:Industry, Academia, Schools Pupils, Teachers and Career Officers and

the general public

Undertaking specific tailored activities to successfully reach our identified target audiences with relevant science communications

• Reached the following target audience contact points since the LATEST2 Programme commenced in July 2010

Schools and colleges: 5400 Industry and Academia : 2300 Community : 157000

Currently securing additional funding and developing new initiatives to drive the IMPACT forward

LATEST2-Outreach Overview

Research activities directed to an important strategic research theme and manufacturing base- shaping capability (focus on UK strengths). Alignment with TSB and related collaboration to accelerate exploitation (increased TRL and scale up) Key challenges identified and reviewed, and addressed in innovative research packages with national and international collaborators- shaping capability and delivering impact (focus on challenges)

Creating and sustaining research scientists and engineers in the) UK and beyond- established leaders and developing leaders (CDT)

Ambassador roles for materials in engineering and physical sciences through extensive outreach activities- delivering impact

LATEST2: SUMMARY