Steels and Ferrous Metals

David Naylor

University Liaison Manager

Swinden Technology Centre

Corus plc

EPSRC Metallurgy Research, Present and FutureBirmingham, March 29th 2001

Metals?

• Who wants to be a Millionaire?

• Starting with the lowest, put these metals in order of annual production

Metals?

• Who wants to be a Millionaire?

• Starting with the lowest, put these metals in order of annual production

Aluminium

Steel Copper

Zinc

Global Metal Production

• Zinc 7

• Copper 12

• Aluminium 21

• Steel 788

million tonnesMetal

The future?

• Steel is vital to UK competitiveness and quality of life

• Globalisation of suppliers and users of steel

• Changing needs of customers

• The environment and sustainable development

Market Demands for Metals• Cheaper and Better Value

– Lower Life Cycle Costs– Multi-materials System Solutions

• Better Quality• Better and More Consistent Properties and Improved

Performance– Stronger, Tougher – More Resistance to Corrosion, Wear and High Temperatures– More Weldable, Formable, Machinable

• Sustainable Materials• Design for Disassembly

Compare Steel with Potatoes!

Construction

Transport

ULSAB concept model

Engineering

Packaging

Narrow & plated strip for batteries

Packaging for food & drink

Other markets & applications

Current Innovations in Steels

• Steel Productivity in UK increased 5 fold in last 20 years – 3 times faster than UK manufacturing

• 70% of steels in cars today were developed in last 10 years

• Composition control in parts per million in 300 tonne casts

• Advanced Process Control, Sensors and Models• Systems Solutions

– Design, Materials and Fabrication Technologies

Future Research in Ferrous Metallurgy

• Lower Costs• Integrated Models from Process to Products and

Applications• Sensors and Process Control in hot, rapidly

moving environments– Temperature, Dimensions, Shape, Composition,

Microstructure, Inclusions, Defects

• Better Quality and Properties• Improved Performance under increasingly arduous

conditions and environments– Higher temperatures, pressures, more corrosive

Future Research in Ferrous Metallurgy

• New Alloys• New Shapes and Net Shapes• Added Value

– Surface Engineering – Smart Surfaces

• New Designs• New Combinations of Metals and Materials• New Fabrication Technologies• Cheap Rapid Prototyping for steel intensive

applications• Systems Solutions, combining material selection

and development, design and fabrication

Future Research in Ferrous Metallurgy

• Recyclable, Durable and Sustainable• A Multi-Disciplinary Team Approach is needed• Support the Supply Chain and Down-stream activites• Important Role for a UK Metals Research Centre

– Provide Synergy for research between industry and academia– Provide large scale multi-user facilities– Better Networking

• International research on Hydrogen Economy– Iron ore reduction and non-fossil fuel energy

• Availability of young researchers to work in these issues?