Future Liquid Metal Engineering Hub

Lead Research Organisation: Brunel University London
Department Name: BCAST

Abstract

Natural resources are the foundation of our life on Earth, without which neither our economy nor society can function. However, due to continued resource overconsumption and the rapidly increasing world population, the global demand for natural resources and the related intense pressure on our environment have reached an unprecedented and unsustainable level. A shocking fact is that our cumulative consumption of natural resources over the last 60 years is greater than that over the whole of previous human history. With an anticipated world population of 9.3bn in 2050, the predicted global natural resource consumption will be almost tripled. This level of overconsumption is obviously not sustainable, and there is a compelling need for us to use our advanced science and technology to work with, rather than to exploit, nature.

Metallic materials are the backbone of manufacturing and the fuel for economic growth. However, metal extraction and refining is extremely energy intensive and causes a huge negative impact on our environment. The world currently produces 50MT of Al and 2bnT of steel each year, accounting for 7-8% of the world's total energy consumption and 8% of the total global CO2 emission. Clearly, we cannot continue this increasing and dissipative use of our limited natural resources. However, the good news is that metals are in principle infinitely recyclable and that their recycling requires only a small fraction of the energy required for primary metal production. Between 1908 and 2007 we produced 833MT of aluminium, 506MT of copper and 33bnT of steels. It is estimated that more than 50% of this metal still exists as accessible stock in our society. Such metal stock will become our energy "bank" and a rich resource for meeting our future needs.

The UK metal casting industry adds £2.6bn/yr to the UK economy, employs 30,000 people, produces 1.14bnT of metal castings per year and underpins the competitive position of every sector of UK manufacturing. However, the industry faces severe challenges, including "hollowing-out" over the past 30 years, increasing energy and materials costs, tightening environmental regulations and a short supply of skilled people. We are now establishing the Future Liquid Metal Engineering Hub to address these challenges. The core Hub activities will be based at Brunel strongly supported by the complementary expertise of our academic spokes at Oxford, Leeds, Manchester and Imperial College and with over £40M investment from our industrial partners. The Hub's long-term vision is full metal circulation, in which the global demand for metallic materials is met by a full circulation of secondary metals (with only limited addition of primary metals each year) through reduced usage, reuse, remanufacture, closed-loop recycling and effective recovery and refining of secondary metals. This represents a paradigm shift for metallurgical science, manufacturing technology and the industrial landscape. The Hub aims to lay down a solid foundation for full metal circulation, demonstrated initially with light metals and then extended to other metals in the longer term. We have identified closed-loop recycling of metallic materials as the greatest challenge and opportunity facing global manufacturing industry, and from this we have co-created with our industrial partners the Hub's research programme. We will conduct fundamental research to deliver a nucleation centred solidification science to underpin closed-loop recycling; we will carry out applied research to develop recycling-friendly high performance metallic materials and sustainable metal processing technologies to enable closed-loop recycling; we will operate a comprehensive outreach programme to engage potential stakeholders to ensure the widest possible impact of our research; we will embed a centre for doctoral training in liquid metal engineering to train future leaders to deliver long-lasting benefits of closed-loop recycling.

Planned Impact

Academic Impact:
The scientific deliverables from the Future LiME Hub represent major advances in solidification science, physical metallurgy, advanced alloy development and resource efficient manufacturing technologies. This knowledge will advance solidification science and will deliver in the long term a nucleation-centred solidification science, which will inspire other researchers for further scientific advance in the field. The academic impact on the wider scientific research community will be significant since nucleation is a widespread phenomenon in nature and technology. For example, it plays a prominent role in condensation and evaporation, crystal growth, deposition of thin films and overall crystallisation. Our research outcomes on nucleation mechanisms and basic techniques for nucleation control will be directly or indirectly applicable to these wider scientific and technological research fields.

Technological Impact:
The Hub's key technological deliverables are recycling-friendly advanced light alloys and sustainable metal processing technologies. Initial technological impact will be in the UK automotive industry and its supply chain and then the wider transportation industry. They will benefit because for the first time they will have direct access to a dedicated Hub for high performance metallic materials and sustainable metal processing technologies. The Hub will be a technology proving ground, and will provide: (1) a shortened lead time from technology concept to industrial production; (2) advanced manufacturing technologies to provide technological advantages over competitors; (3) recycling-friendly advanced metallic materials with reduced cost; and (4) improved sustainability due to reduced CO2 emissions, conservation of natural resources and consequently reduced environmental impact. This will make a major contribution to rebalancing the UK economy.

Environmental Impact:
The potential environmental sustainability impact of the Hub's research is profound as the research and industrial application outputs will have a dramatic influence on curbing the carbon emissions from the global automotive fleet. The research output of closed-loop recyclable light alloys and advanced processing technologies represents a vital strand of an integrated national approach to transport decarbonisation. Closed-loop recycling of aluminium alloys for weight reduction of the world's automotive vehicles fleet has the potential to progressively replace millions of tonnes of steel. Every million tonnes of recycled aluminium used saves a million tonnes of carbon each year from reduced fuel consumption and reduces by 95% the carbon emissions from primary aluminium production.

Economic Impact:
Our Hub programme has the potential to transform the traditional primary metals based industries in the UK and the wider world making them far more sustainable and less dependent on energy hungry primary metal sources. The UK is a net exporter of aluminium scrap to China and India and this is a loss of an extremely valuable resource. The export of aluminium scrap is about 800kT each year so retaining and recycling this in the UK into high value automotive castings, extrusions and sheet for lightweight vehicles can be estimated to be worth about £800 million in terms of added value each year. The overall cumulative contribution to the UK economy would be in billions of pounds over the next 10-20 years. The Hub's research programme will demonstrate that aluminium scrap is an energy bank and a viable source for the manufacture of high integrity automotive structures, and chassis and powertrain components.

Benefit to Society:
The ultimate benefit to society as a whole will be improved quality of life. Society will ultimately benefit from improved air quality through reduced pollution related health problems, increased job opportunities, cleaner and more efficient transport systems, and an enhanced national economy.

Organisations

Publications

10 25 50
 
Description The Hub's research activities are organised into 6 research themes:
• Understanding of atomistic mechanisms of heterogeneous nucleation.
• Understanding of grain initiation and grain refinement during solidification.
• Understanding the formation of Fe-containing intermetallics (IMCs) during solidification.
• Development of closed-loop recyclable high performance light alloys.
• Development of the multi-purpose high shear technology and its applications to metal casting processes.
• Realising the impact of the Hub's research through industrial collaborative research projects.

Significant progress has been made since the Hub's establishment in all aspects of our research:

• Fundamental research activities have resulted in the establishment of the early stages of solidification covering the prenucleation phenomenon, atomistic 3-layer nucleation mechanisms, constrained and unconstrained cap formation, progressive and explosive grain initiation behaviour, grain initiation maps, grain refinement maps, grain refinement by native oxides, manipulation of heterogeneous nucleation by controlled interfacial segregation. This has led to over 309 high quality journal publications, and 120 plenary/keynote/invited lectures at key international conferences. Perhaps more importantly we see this as the emergence of a framework for the nucleation-centred solidification science.

• Applied research activities have seen a number of closed-loop recyclable high performance Al-alloys and a number of resource efficient metal processing technologies being developed, patented, and tested industrially and some of them being licensed for commercial exploitation. For instance, the patented high strength Al casting alloy has been licensed for commercial production of aerospace components, and the patented MC-DC casting technology for commercial production of high quality magnesium billets.

• Industrial engagement has significantly increased in the last 6 years. The number of industrial collaborators has increased from the original 17 to 66. In particular, we have developed an effective approach to support industrial research and development. These include: (1) Co-funding (between LiME and Industry) industrial research fellows, 7 industrial fellows so far; (2) supporting/participating industrial research through Innovate UK funded industrial collaborative projects, 14 projects totaling £12M grant income so far; (3) Establishing the Constellium R&D Centre for Automotive structures at Brunel with over 40 research engineers; and (4) supporting SMEs through our "LiME Technology Playground" mechanism.

• Community building: Six feasibility studies have been funded by the LiME Hub at different institutions, including Loughborough, Swansea and Warwick Universities. These studies widen the range of materials and industrial sectors the Hub is directly supporting. These short-term projects of up to 6 months have enabled the study of key challenges in one or more of three distinct areas: (1) heterogeneous nucleation; (2) grain refinement and (3) recycling of metallic materials. The studies are intended to enable proof-of-concept results to be successfully obtained ready for preparation of grant proposals to relevant funding bodies including EPSRC, Innovate UK, EU and industry.

• A new Future Metallurgy Centre has been constructed at Brunel University London, which the LiME Hub will be integral in establishing. The Hub has enabled this successful bid to be placed, highlighting the world leading research which is being conducted within. This £16 million grant from the Research England UKRPIF has been significantly match funded by industrial partners. The investment in the facility will include new state of the art instruments for materials characterisation that will provide opportunities for growth in the Hub's research fields. The new facility will enable fundamental research to take place in order to develop a foundation for new and innovative solutions to industry requirements. This research will then be passed quickly and easily to our existing facilities for scale-up activities and validation.

• More importantly, the Hub's vision for full metal circulation and research outcomes have led to the successful establishment of an Inter-disciplinary circular economy research centre in Circular metals funded by UKRI, CircularMetal for short. The research activities in the centre include: (1) development of ultrahigh performance multi-component alloys for reduced usage; development of "Metal Health Service" (MHS) system for substantial increase of service life; circular business covering product design, business models and supply chain management; circular economics and circular society.
Exploitation Route Since its start in November 2015, the Hub team has been striving for industrial engagement. We have developed the following strategies for engaging with potential industrial collaborators:

• Establishing industrial research fellowships co-funded by the Hub and the industry with varying proportions of funding. This mechanism is particularly suitable for supporting companies with medium and long-term challenges. So far, we have set up 6 industrial research fellowships: 3 with JLR, 2 with Constellium, 1 with MQP and 1 with SAPA. Establishing industrial fellowships with Aeromet, Grainger and Worrall and Chinalco are in progress.

• Developing strategic partners: This approach aims to develop multidimensional long-term academia-industry collaboration with significant scale. A good example of such an engagement is with Constellium. Constellium co-funded a research fellowship in 2011 with the then EPSRC Centre - LiME; became a partner of the AMCC at Brunel in 2013 and more recently of the AMPC; established the Constellium UTC at Brunel in 2016, and opened the Constellium R&D Centre for Automotive Structures at Brunel in 2018. Now, Constellium is continuing to invest significant cash funding into the research activities at Brunel. Constellium is engaged side by side with BCAST on the LiME Hub and a number of other leveraged programmes including the AMCC/AMPC and STEP-Al, and additionally on applied InnovateUK projects. In order to deliver these activities, Constellium is collectively resourcing a pool of 50 people of NVQ Level 3 (apprentice) to postdoctoral researcher including directly funding 2 PDRAs on LiME, 2 PDRAs on AMCC/AMPC and 6 PDRAs on the STEP-Al programmes. Constellium is also currently funding 8 PhDs (iCASE Awards) at Brunel University.

• Setting up national scale-up facilities: We have established large scale metal casting and processing facilities funded by EPSRC and HEFCE and housed in the purpose built Advanced Metal Casting Centre (AMCC) and Advanced Metal Processing Centre (AMPC). This allows us to address effectively "the valley of death" and to bridging a clear gap left by other public investment.

• Setting up a new fundamental research facility: A new award, funded by Research England UKRPIF will enable the construction of the Future Metallurgy Centre (FMC) at Brunel University London. This application was heavily supported by the LiME Hub which will be integrated within it. The FMC will enable fundamental research to take place within the Hub at TRL levels 1-3 before being passed onto our existing scale-up facilities, AMCC and AMPC.

• Supporting industrial research through Innovate UK funded industry-led collaborative research projects. Through such projects, we either scale-up the technology concepts developed by the Hub or deploy the Hub's expertise and facilities to support industrial research.

• Building "The LiME Technology Playground" as a platform to support industrial R&D. This is the mechanism by which we make the Hub's expertise and facilities available to the wider manufacturing community, particularly to SMEs. It works in two distinctive ways: (1) companies try out their technology ideas in the Hub using our expertise and/or facilities; and (2) industrial companies work with us closely to generate new technology ideas. Both ways have been proven to be effective by a number of successful cases. Extensive engagement with the manufacturing industry has resulted in significant knowledge exchange between the academia and the industry. Such knowledge exchange follows the following 4 mechanisms:
• Technology transfer through licensing: 3 patented technologies (1 high strength cast Al-alloy, 1 grain refiner and 1 casting technology) have been licenced to industrial companies for commercial exploitation.
• Technology input to Innovate UK funded industrial collaborative projects: The patented technology concepts (TRL < 3) developed within the Hub programme are granted to the partners of the IUK-funded projects for further development (usually granting a non-exclusive free license to the project partners) governed by the collaboration agreement.
• People exchange: We realise that the most effective route for knowledge exchange is through people exchange. Constellium is collectively resourcing a pool of 50 people of NVQ Level 3 (apprentice) to postdoctoral researcher including directly funding 2 PDRAs on LiME, 2 PDRAs on AMCC/AMPC and 6 PDRAs on the STEP-Al programmes. Constellium is also currently funding 4 PhDs (iCASE Awards) at Brunel University. Constellium have employed a number of Brunel researchers directly into their business. People exchange has been one of the key factors for the success of the Brunel-Constellium collaboration.
• Informing the general community: For example, we have hosted 2 prestigious international conferences (SP17 and Mg18) to showcase the Hub's research on the international stage and 3 open-day events to inform the national community about our research outcomes. Furthermore, in December 2019 the Hub hosted an aluminium in aerospace event with an aim to broaden the Hub's sector alignment with aerospace OEMs and their casting supply chains. In addition to the aforementioned activities for engaging research collaborators, we have developed the following approaches to engage the wider community to maximise the benefit of the Hub's research outcomes.

• Coordinated group presentations at targeted international conferences: These include: ICAA16, Solidification and Gravity 2018, International Conference on Magnesium (ICM6), ICSSP-7 etc.

• Working closely with trade organisations and learned societies: The Hub has members on the boards of ICME (the Institute of Cast Metal Engineers, AlFed (Aluminium Federation) and CMF (Cast Metal Federation), Alupro (aluminium packaging recycling organisation) and Chairman/Co-Chairman of Light Metals Division and Solidification and Casting Society of IOM3 (the Institute of Materials, Minerals and Mining). Partnerships with such organisations help us to reach a wide range of industrial companies and individuals. Working with the Aerospace Technology Institute (ATI) on the development of a new UK Near Net Shape strategy, with a focus on aluminium castings. As part of the first stage of this strategy, the Hub is engaging with a wide range of aerospace OEMs including: Rolls Royce Plc, Spirit AeroSystems, Airbus, GKN, GE and Leonardo Helicopters. The next stage will engage with their supply chains (typically casting SMEs), forming a UK aluminium casting consortium. The consortium will then be brought together to develop a UK aluminium casting roadmap, later in 2020. This roadmap will feed directly into the ATI materials and manufacturing UK strategy for civil aircraft, which aligns with the wider High Value Manufacturing Catapult strategy.
Sectors Aerospace, Defence and Marine,Construction,Education,Manufacturing, including Industrial Biotechology,Transport

 
Description The ultimate vision of the Future LiME Hub is full metal circulation. We are working towards delivering a research programme spanning fundamental nucleation research, materials development, technology innovation and industrial applications. Realisation of full metal circulation in the context of a circular economy is a global challenge and requires the joint efforts of academia, industry, government and society as a whole. The Hub has taken a leadership role on behalf of UK plc and has developed an extensive outreach programme to engage all potential stakeholders to deliver the widest impact. Economic Impact: The Hub is working towards transforming the traditional primary metals based aluminium and magnesium industries in the UK and the wider world making them far more sustainable and less dependent on energy hungry primary metal sources. Although recycled aluminium is used for the manufacture of low grade castings for automotive applications, it is not used for the manufacture of automotive sheet or high performance shaped products that are required for lightweight structures and powertrains. The UK is a net exporter of aluminium scrap to China and India and this is a loss of an extremely valuable resource. The Hub's research programme is demonstrating that aluminium scrap is an energy bank and viable source for the manufacture of high integrity automotive structures and chassis and powertrain components. A key example is the Hub's direct collaboration with Constellium who is a manufacturer of automotive aluminium materials and extrusions. Constellium collaborates directly with the Hub's research programme and has set up additional research projects to advance their materials development, processing and recycling capabilities. Advancing their research and development capabilities within Brunel University London has enabled them to further collaborate with OEMs, including Jaguar Land Rover, Toyota, Nissan, etc., to name just a few. Furthermore, Constellium have set up their University Technology Centre (UTC) with Brunel the partnership is utilising the purpose-built scale-up facilities to develop structures including battery boxes and crash management systems. Success of this partnership has attracted Constellium to expand their footprint at Brunel with the launch of their automotive R&D centre in June 2018. From this advancement in their UK based capability, Constellium product sales to OEMs are on the rise and are supporting the UK's economic competitiveness in the global market. Benefit to Society: The ultimate benefit to society from the Hub research programme will be improved quality of life. Society will ultimately benefit from improved air quality through reduced pollution related health problems, increased job opportunities, cleaner and more efficient transport systems, and improved national economy. We are currently working directly with OEMs and their supply chains to reduce the use of primary metals to 25%. Therefore, by using 75% secondary materials, each year we would save 219MT bauxite and 2.06TkWh electricity (equivalent to 6 times the UK's annual electricity consumption), and reduce CO2 emission by 784MT. Policy and Environmental Impact: The Hub's long term goal is to create an optimised metallurgical industry based on full metal circulation, which represents a specific implementation of the wider concept of a circular economy. We are currently working with the automotive council and have aligned the Hub's strategic vision of closed-loop recycling to their market determined product drivers and end-of-life vehicle (ELV) analysis. An internal workshop was held by the Hub in May 2018 to map our research directly to these, and to the ELV directive. This will further build on our current alignment, and continually ensure the research is aligned to the automotive industrial lightweighting requirements (short term 50% weight reduction) and how material resources can be effectively recovered, by delivering our novel recycling principles. OEMs working with the Hub have made a major advance in vehicle body lightweighting with world-leading use of aluminium and magnesium alloys and have highlighted the need for the maximum use of recycled metal from production and end of life. As a result of our engagements with the Aerospace industry, the ATI have incorporated aluminium shape casting directly into the UK strategy for component manufacture. To retain and build on this lead the Future LiME Hub is advancing its exploitation of recycling-friendly alloys and sustainable processing technologies.
Sector Aerospace, Defence and Marine,Education,Manufacturing, including Industrial Biotechology,Transport
Impact Types Societal,Economic

 
Description Metallurgical training for all, PhDs, researchers and staff members working within the Future LiME Hub
Geographic Reach Local/Municipal/Regional 
Policy Influence Type Influenced training of practitioners or researchers
Impact To advance skillset of workforce to enhance research efficiency and effectiveness within the Future LiME Hub.
 
Description "Grain refiner technology" for lightweight magnesium alloys - iCURE
Amount £15,000 (GBP)
Organisation Innovate UK 
Sector Public
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Description (AMCC2) Advanced Metals Casting Centre Phase II
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Sector Public
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Description Constellium - LiME Sponsored Fellowship
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Sector Private
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Sector Public
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Sector Public
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Organisation Innovate UK 
Sector Public
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Sector Private
Country United Kingdom
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Description Future Manufacturing Hub in Manufacture using Advanced Power Processes
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Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start  
 
Description Future Metallurgy Centre
Amount £16,000,000 (GBP)
Funding ID Future Metallurgy Centre 
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Department Research England
Sector Public
Country United Kingdom
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Description Generation of stronger age hardening aluminium alloys based on a novel thermomechanical processing route
Amount £25,000 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 07/2016 
End 03/2017
 
Description Grain Refiner - Industry testing
Amount £153,791 (GBP)
Organisation CBMM Technology Suisse 
Sector Private
Country Switzerland
Start 05/2016 
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Description High Performance Magnesium cylinder
Amount £205,965 (GBP)
Funding ID HPMaC 
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Sector Private
Country Sweden
Start 06/2020 
End 05/2021
 
Description High Strength and ductile aluminium castings for hybrid chassis structure (SADAC)
Amount £368,289 (GBP)
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 08/2018 
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Description ICASE Studentship - V de Stefano
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Organisation Constellium 
Sector Private
Country France
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Description ICURe: SETsquared award
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Funding ID 14-08/518470147 
Organisation Innovate UK 
Sector Public
Country United Kingdom
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Organisation Constellium 
Department Constellium UK Ltd
Sector Private
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Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
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Sector Private
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Description JLR iCase Studentship - LUKE DORAN
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Funding ID icase 18000094 
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Department Jaguar Land Rover
Sector Private
Country United Kingdom
Start 10/2019 
End 09/2024
 
Description Joining Dissimilar Materials for Future Automotive Structures - Developing New Resistance Welding Technologies to Create High Integrity Multi-Material Joints
Amount £42,000 (GBP)
Organisation TWI ltd 
Sector Private
Country United Kingdom
Start 06/2016 
End 05/2019
 
Description Leadfree Explosive Cord
Amount £71,706 (GBP)
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 08/2015 
End 01/2017
 
Description Lightweight Electric Vehicle Architecture (LEVA)
Amount £231,518 (GBP)
Organisation Advanced Propulsion Centre 
Sector Charity/Non Profit
Country United Kingdom
Start 10/2020 
End 09/2021
 
Description Lightweight Innovative Battery Enclosures using Recycled Aluminium TEchnologies
Amount £375,762 (GBP)
Funding ID 28979 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 07/2019 
End 06/2021
 
Description Machine learning guided alloy design and thermomechanical process optimisation for high performance automotive aluminium alloys
Amount £27,765 (GBP)
Organisation Constellium 
Sector Private
Country France
Start 10/2020 
End 09/2024
 
Description Made Smarter Innovation - Materials Made Smarter Research Centre
Amount £4,049,203 (GBP)
Funding ID EP/V061798/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 08/2021 
End 02/2025
 
Description Manufacturing of lightweight structural components for high performance electrical machines by electromagnetic pulse technology (EMPT)
Amount £62,471 (GBP)
Funding ID R/155683 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2021 
End 09/2021
 
Description Melt Conditioned Direct Chill Casting of Aluminium Alloys
Amount £340,000 (GBP)
Organisation SAPA 
Sector Private
Country Norway
Start 07/2016 
End 12/2019
 
Description Microstructural control during Melt Conditioned DC (MCDC) casting process
Amount £27,765 (GBP)
Organisation Constellium 
Sector Private
Country France
Start 01/2020 
End 12/2023
 
Description NSIRC Studentship: M KHAIRY
Amount £42,000 (GBP)
Funding ID MK032019BRU 
Organisation TWI The Welding Institue 
Sector Private
Country United Kingdom
Start 03/2019 
End 03/2022
 
Description Near-Net shaped bulk MgB2 superconductors
Amount £193,037 (GBP)
Organisation University of Cambridge 
Sector Academic/University
Country United Kingdom
Start 04/2016 
End 04/2018
 
Description Next Generation of Automotive Casting Alloys
Amount £822,000 (GBP)
Organisation Jaguar Land Rover Automotive PLC 
Department Jaguar Land Rover
Sector Private
Country United Kingdom
Start 09/2016 
End 09/2019
 
Description Next generation of free machining aluminium alloys
Amount £27,765 (GBP)
Organisation Constellium 
Sector Private
Country France
Start 10/2020 
End 09/2024
 
Description Non-Equilibrium Solidification, Modelling For Microstructure Engineering Of Industrial Alloys (NEQUISOL IV)
Amount £442,538 (GBP)
Organisation European Space Agency 
Sector Public
Country France
Start 03/2021 
End 03/2022
 
Description Novel processing of 6xxx alloys for automotive applications
Amount £27,765 (GBP)
Funding ID 2035781 
Organisation Constellium 
Sector Private
Country France
Start 10/2017 
End 09/2021
 
Description Novel processing of 6xxx alloys for automotive applications - iCASE Studentship Chrysoula Tzileroglou
Amount £83,296 (GBP)
Funding ID 2035781 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 10/2017 
End 09/2022
 
Description Performance-driven design of aluminium alloys for additive manufacturing (PAAM)
Amount £477,459 (GBP)
Funding ID EP/W00593X/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2023 
End 01/2026
 
Description PhD Studentship - Aluminium Alloy Development - Jiao Fang
Amount £37,000 (GBP)
Organisation Jaguar Land Rover Automotive PLC 
Department Jaguar Land Rover
Sector Private
Country United Kingdom
Start 01/2016 
End 01/2019
 
Description Prediction of Engineering Properties of Thermomechanically Treated Aluminium Alloys. Prof. Hamid Assadi Brunel Centre for Advanced Solidification Tech
Amount £29,232 (GBP)
Funding ID 2625243 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2021 
End 12/2024
 
Description Recycled Aluminium Through Innovative Technology (REALITY)
Amount £299,428 (GBP)
Funding ID 102797 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 06/2017 
End 03/2020
 
Description STEP Aluminium 2018 (STEP AL)
Amount £2,198,606 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 12/2018 
End 09/2023
 
Description Specialised Thimbles for Offshore Renewable Marine Energy Structures (STORM)
Amount £101,149 (GBP)
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 02/2017 
End 01/2018
 
Description Strain Enhanced Precipitation (STEP)
Amount £2,219,000 (GBP)
Organisation Constellium 
Sector Private
Country France
Start 12/2018 
End 11/2023
 
Description Synergetic effect of surface-active metallic additions on structure modification in aluminium alloys
Amount £27,765 (GBP)
Organisation Constellium 
Sector Private
Country France
Start 10/2020 
End 09/2024
 
Description Synthetic biology system for lightweight boron carbide composite armour (SynBA)
Amount £285,546 (GBP)
Organisation Defence Science & Technology Laboratory (DSTL) 
Sector Public
Country United Kingdom
Start 10/2017 
End 09/2019
 
Description The Materials Research Society (MRS) Spring Meeting (IAA)
Amount £11,500 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 12/2016 
End 04/2017
 
Description The development of next generation antibacterial Ti implants with integrated chemical and topographical modifications
Amount £12,000 (GBP)
Organisation The Royal Society 
Sector Charity/Non Profit
Country United Kingdom
Start 03/2018 
End 03/2020
 
Description UKRI Interdisciplinary Centre for CircularMetal
Amount £4,437,439 (GBP)
Funding ID EP/V011804/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2021 
End 12/2024
 
Description Understanding Intermetallic Compound Nucleation and Growth using Simultaneous Radiography and Pixel based Spectroscopy
Amount £45,000 (GBP)
Organisation SOLEIL Synchrotron 
Sector Academic/University
Country France
Start 04/2018 
End 04/2018
 
Description Virtual Engineering Laboratory
Amount £255,000 (GBP)
Organisation The Wolfson Foundation 
Sector Charity/Non Profit
Country United Kingdom
Start 01/2016 
End 06/2018
 
Description Wear resistant austempersed ductile iron for camshaft in automotive engine - IAA
Amount £19,900 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 07/2017 
End 07/2019
 
Title Data for "Comparative Analysis of Structure and Properties of Nb-B Inoculated Direct Chill Cast AA4032 Alloy Extruded from As-Cast and Homogenized Conditions" 
Description The raw data acquired for the work shown in this publication. 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
URL https://brunel.figshare.com/articles/dataset/Data_for_Comparative_Analysis_of_Structure_and_Properti...
 
Title Data for "Comparative Analysis of Structure and Properties of Nb-B Inoculated Direct Chill Cast AA4032 Alloy Extruded from As-Cast and Homogenized Conditions" 
Description The raw data acquired for the work shown in this publication. 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
URL https://brunel.figshare.com/articles/dataset/Data_for_Comparative_Analysis_of_Structure_and_Properti...
 
Title Numerical studies of batch and inline high shear melt condi-tioning technology using different rotors dataset 
Description This collection contains data from the article: G.S.B. Lebon, J.B. Patel, and Z. Fan. Numerical studies of batch and inline high shear melt conditioning technology using different rotors. Crystals. 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
URL https://brunel.figshare.com/articles/dataset/Numerical_studies_of_batch_and_inline_high_shear_melt_c...
 
Title Numerical studies of batch and inline high shear melt conditioning technology using different rotors dataset 
Description This collection contains data from the article: G.S.B. Lebon, J.B. Patel, and Z. Fan. Numerical studies of batch and inline high shear melt conditioning technology using different rotors. Crystals. 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
URL https://brunel.figshare.com/articles/dataset/Numerical_studies_of_batch_and_inline_high_shear_melt_c...
 
Title Numerical studies of batch and inline high shear melt conditioning technology using different rotors dataset 
Description This collection contains data from the article: G.S.B. Lebon, J.B. Patel, and Z. Fan. Numerical studies of batch and inline high shear melt conditioning technology using different rotors. Crystals. 
Type Of Material Database/Collection of data 
Year Produced 2022 
Provided To Others? Yes  
URL https://brunel.figshare.com/articles/dataset/Numerical_studies_of_batch_and_inline_high_shear_melt_c...
 
Description Alliance Casting European Development Centre ACE-DC 
Organisation Huttenes-Albertus UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution The collaboration will create the first Alliance Casting European Development Centre for Nissan. ACE-DC develops and launches innovative products and casting technology in relation to engine and vehicle components. A key part is the expertise provided by each consortium member: Brunel University's research and expertise in melt conditioning and liquid metal engineering.
Collaborator Contribution HAUK will provide advanced core-making technology including inorganic 3D core printing technology; Lighthouse systems developing a new mobile application (HTML5) to access their data integration and Manufacturing Execution Systems (MES) for OEE and quality management. Applied technology centres on the development of lighter and stronger cylinder heads resulting in better fuel consumption, reduced emissions, and improved power to weight ratios. The products will be used both in the UK and exported to Renault plants. t
Impact This collaboration further created a number of jobs. Outcomes to be detailed on project completion.
Start Year 2017
 
Description Alliance Casting European Development Centre ACE-DC 
Organisation Lighthouse Systems Ltd
Country United Kingdom 
Sector Private 
PI Contribution The collaboration will create the first Alliance Casting European Development Centre for Nissan. ACE-DC develops and launches innovative products and casting technology in relation to engine and vehicle components. A key part is the expertise provided by each consortium member: Brunel University's research and expertise in melt conditioning and liquid metal engineering.
Collaborator Contribution HAUK will provide advanced core-making technology including inorganic 3D core printing technology; Lighthouse systems developing a new mobile application (HTML5) to access their data integration and Manufacturing Execution Systems (MES) for OEE and quality management. Applied technology centres on the development of lighter and stronger cylinder heads resulting in better fuel consumption, reduced emissions, and improved power to weight ratios. The products will be used both in the UK and exported to Renault plants. t
Impact This collaboration further created a number of jobs. Outcomes to be detailed on project completion.
Start Year 2017
 
Description Alliance Casting European Development Centre ACE-DC 
Organisation Nissan Motor Manufacturing Ltd
Country United Kingdom 
Sector Private 
PI Contribution The collaboration will create the first Alliance Casting European Development Centre for Nissan. ACE-DC develops and launches innovative products and casting technology in relation to engine and vehicle components. A key part is the expertise provided by each consortium member: Brunel University's research and expertise in melt conditioning and liquid metal engineering.
Collaborator Contribution HAUK will provide advanced core-making technology including inorganic 3D core printing technology; Lighthouse systems developing a new mobile application (HTML5) to access their data integration and Manufacturing Execution Systems (MES) for OEE and quality management. Applied technology centres on the development of lighter and stronger cylinder heads resulting in better fuel consumption, reduced emissions, and improved power to weight ratios. The products will be used both in the UK and exported to Renault plants. t
Impact This collaboration further created a number of jobs. Outcomes to be detailed on project completion.
Start Year 2017
 
Description Alliance Casting European Development Centre ACE-DC 
Organisation Zero Carbon Futures Ltd
Country United Kingdom 
Sector Private 
PI Contribution The collaboration will create the first Alliance Casting European Development Centre for Nissan. ACE-DC develops and launches innovative products and casting technology in relation to engine and vehicle components. A key part is the expertise provided by each consortium member: Brunel University's research and expertise in melt conditioning and liquid metal engineering.
Collaborator Contribution HAUK will provide advanced core-making technology including inorganic 3D core printing technology; Lighthouse systems developing a new mobile application (HTML5) to access their data integration and Manufacturing Execution Systems (MES) for OEE and quality management. Applied technology centres on the development of lighter and stronger cylinder heads resulting in better fuel consumption, reduced emissions, and improved power to weight ratios. The products will be used both in the UK and exported to Renault plants. t
Impact This collaboration further created a number of jobs. Outcomes to be detailed on project completion.
Start Year 2017
 
Description CSIRO (T-Mag Casting Technology) 
Organisation Commonwealth Scientific and Industrial Research Organisation
Country Australia 
Sector Public 
PI Contribution Work conducted to integrate the first industrial application of our new Rotor/Stator high shear melt conditioning technology for production of automotive components with improved quality and for applications to recycling magnesium alloy scrap.
Collaborator Contribution They integrated the new high shear melt conditioning technology within their 100kg magnesium alloy melting and casting furnace to evaluate the benefits of high shear melt conditioning on the quality of casting in terms of microstructure refinement, reduced oxide film defects and enhanced mechanical properties.
Impact Successful integration and output of new technology to provide the company with improved output of products.
Start Year 2015
 
Description Characterizing Gallium-Based Metal Flow With Surface Oxidization 
Organisation University of Surrey
Country United Kingdom 
Sector Academic/University 
PI Contribution An award of £37,235.14 at 100% FEC (£29,788.11 at 80% FEC) has been given by the LiME Hub to University of Surrey for the feasibility study of Characterizing Gallium-Based Metal Flow With Surface Oxidization.
Collaborator Contribution £37,235.14 at 100% FEC (£29,788.11 at 80% FEC)
Impact We aim to use a new testbed that is currently being built at the University of Surrey to perform fundamental research into the hydrodynamic behavior of a GaIn liquid metal alloy. Collect data that will help us to characterise hydrodynamic properties, material physics, and chemistry of liquid-metal. Engage with the wider academic and industrial community to collaborate towards realising the material's potential
Start Year 2020
 
Description Chinalco - Strategic partnership and trials. 
Organisation Aluminum Corporation of China (Chinalco)
Country China 
Sector Private 
PI Contribution Initial development of a strategic partnership led to the implementation of trials. Trials of 7xxx and 4xxx series Al-alloys using the MC-DC technology at the Chinalco facility in China. Trials were conducted to evaluate the benefits of melt conditioning in regards to producing large diameter billets for forging stock with better microstructure and reduced chemical segregation.
Collaborator Contribution Use of their manufacturing facility in China.
Impact Evaluation of the benefits of melt conditioning to produce large diameter billets for forging stock, where better microstructure and reduced chemical segregation were among the key achievements.
Start Year 2015
 
Description Constellium - University Technology Centre (UTC) 
Organisation Constellium
Department Constellium UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution Provides expertise in fundamental investigation for sustainable metals, and the use of the AMCC and AMPC facilities to underpin Constellium's R&D activities.
Collaborator Contribution Constellium established their University Technology Centre (UTC) at Brunel University London's Advanced Metal Casting Centre (AMCC), later including the AMPC.
Impact A dedicated centre of excellence for the design, development and prototyping of aluminium alloys and automotive structural components, the UTC is a unique partnership between industry and academia, bringing the latest research to market. Projects such as LEAAST and CAAHS are examples of outputs.
Start Year 2016
 
Description DSTL - Synthetic biology system for lightweight boron carbide composite armour (SynBA) 
Organisation Advanced Defence Materials
Country United Kingdom 
Sector Private 
PI Contribution Funded by Defence Science & Technology Laboratory. BCAST, Brunel is focussed on the heat treatment and characterisation of graphene incorporated boron carbide matrix composite powders supplied by the academic partner, University of Birmingham.
Collaborator Contribution Academic partner, School of BioSciences, University of Birmingham is concerned with the optimisation of synthetic biology processed graphene incorporated boron carbide composite powders in large quantity scale. Sub-contractor, Kennametal Manufacturing Limited is involved in the consolidation of the graphene incorporated boron carbide composite using industrial scale spark plasma sintering. Sub-contractor, Advanced Defence Materials Limited is involved in the testing of the graphene incorporated boron carbide composite ceramic tiles.
Impact Development of synthetic biology system for lightweight boron carbide composite armour (SynBA). An Invited talk has resulted: I Chang, S. Surbhi, I Mikheenko and L.Macaskie (2018) Synthetic biology system for lightweight boron carbide composite armour, DSTL Synthetic Biology Showcase, 14-15 May 2018, University of Edinburgh, UK. This is a multidisciplinary collaboration involving Materials Science from Brunel and Biosciences from University of Birmingham.
Start Year 2017
 
Description DSTL - Synthetic biology system for lightweight boron carbide composite armour (SynBA) 
Organisation Defence Science & Technology Laboratory (DSTL)
Country United Kingdom 
Sector Public 
PI Contribution Funded by Defence Science & Technology Laboratory. BCAST, Brunel is focussed on the heat treatment and characterisation of graphene incorporated boron carbide matrix composite powders supplied by the academic partner, University of Birmingham.
Collaborator Contribution Academic partner, School of BioSciences, University of Birmingham is concerned with the optimisation of synthetic biology processed graphene incorporated boron carbide composite powders in large quantity scale. Sub-contractor, Kennametal Manufacturing Limited is involved in the consolidation of the graphene incorporated boron carbide composite using industrial scale spark plasma sintering. Sub-contractor, Advanced Defence Materials Limited is involved in the testing of the graphene incorporated boron carbide composite ceramic tiles.
Impact Development of synthetic biology system for lightweight boron carbide composite armour (SynBA). An Invited talk has resulted: I Chang, S. Surbhi, I Mikheenko and L.Macaskie (2018) Synthetic biology system for lightweight boron carbide composite armour, DSTL Synthetic Biology Showcase, 14-15 May 2018, University of Edinburgh, UK. This is a multidisciplinary collaboration involving Materials Science from Brunel and Biosciences from University of Birmingham.
Start Year 2017
 
Description DSTL - Synthetic biology system for lightweight boron carbide composite armour (SynBA) 
Organisation Kennametal Inc
Country United States 
Sector Private 
PI Contribution Funded by Defence Science & Technology Laboratory. BCAST, Brunel is focussed on the heat treatment and characterisation of graphene incorporated boron carbide matrix composite powders supplied by the academic partner, University of Birmingham.
Collaborator Contribution Academic partner, School of BioSciences, University of Birmingham is concerned with the optimisation of synthetic biology processed graphene incorporated boron carbide composite powders in large quantity scale. Sub-contractor, Kennametal Manufacturing Limited is involved in the consolidation of the graphene incorporated boron carbide composite using industrial scale spark plasma sintering. Sub-contractor, Advanced Defence Materials Limited is involved in the testing of the graphene incorporated boron carbide composite ceramic tiles.
Impact Development of synthetic biology system for lightweight boron carbide composite armour (SynBA). An Invited talk has resulted: I Chang, S. Surbhi, I Mikheenko and L.Macaskie (2018) Synthetic biology system for lightweight boron carbide composite armour, DSTL Synthetic Biology Showcase, 14-15 May 2018, University of Edinburgh, UK. This is a multidisciplinary collaboration involving Materials Science from Brunel and Biosciences from University of Birmingham.
Start Year 2017
 
Description DSTL - Synthetic biology system for lightweight boron carbide composite armour (SynBA) 
Organisation University of Birmingham
Department Institute of Applied Social Studies
Country United Kingdom 
Sector Academic/University 
PI Contribution Funded by Defence Science & Technology Laboratory. BCAST, Brunel is focussed on the heat treatment and characterisation of graphene incorporated boron carbide matrix composite powders supplied by the academic partner, University of Birmingham.
Collaborator Contribution Academic partner, School of BioSciences, University of Birmingham is concerned with the optimisation of synthetic biology processed graphene incorporated boron carbide composite powders in large quantity scale. Sub-contractor, Kennametal Manufacturing Limited is involved in the consolidation of the graphene incorporated boron carbide composite using industrial scale spark plasma sintering. Sub-contractor, Advanced Defence Materials Limited is involved in the testing of the graphene incorporated boron carbide composite ceramic tiles.
Impact Development of synthetic biology system for lightweight boron carbide composite armour (SynBA). An Invited talk has resulted: I Chang, S. Surbhi, I Mikheenko and L.Macaskie (2018) Synthetic biology system for lightweight boron carbide composite armour, DSTL Synthetic Biology Showcase, 14-15 May 2018, University of Edinburgh, UK. This is a multidisciplinary collaboration involving Materials Science from Brunel and Biosciences from University of Birmingham.
Start Year 2017
 
Description EPSRC - High Reliability Interconnects: New Methodologies for Pb-free Solders 
Organisation Ford Motor Company
Department Ford Motor Company (France)
Country France 
Sector Academic/University 
PI Contribution Recently started (July 2018) EPSRC funded collaboration. We are working to develop a microstructurally-based predictive model of electronic solder joint behaviour during thermo-mechanical loading that links from the microstructure to the component scale. This involves identifying the optimum joint microstructures through combined micromechanical testing and computational plasticity, and developing methods to generate solder joints with these microstructures by controlling the solidification process.
Collaborator Contribution Partners at the University of Greenwich are linking from the individual joint scale to the full component scale. This is being supported by a collaboration with Ford (USA) who are performing board-level reliability testing under harsh automotive thermal cycling conditions within the international electronics manufacturing initiative. Rolls-Royce are contributing to solder alloy selection studies as they move away from Sn-Pb solders in their applications that have benefitted from exemptions from Pb-free legislation. Together, we are working to improve solder joint reliability in emerging electronic applications.
Impact The intended outcomes are: To develop optimal microstructures for solder joint performance tailored to the specific demands of the application. For example, for an increase in operation temperature capability which can contribute to automotive/aerospace lightweighting by allowing shielding to be removed and electronics to be located closer to sensors with shorter wires, both of which save mass. In safety-critical applications, the critical loading differs significantly from potential impact and accident mitigation in the nuclear energy sector through to elevated temperature high cycle fatigue superimposed on low-cycle thermal cycling in the aero-engine industry.
Start Year 2018
 
Description EPSRC - High Reliability Interconnects: New Methodologies for Pb-free Solders 
Organisation Nihon Superior
Country Japan 
Sector Private 
PI Contribution Recently started (July 2018) EPSRC funded collaboration. We are working to develop a microstructurally-based predictive model of electronic solder joint behaviour during thermo-mechanical loading that links from the microstructure to the component scale. This involves identifying the optimum joint microstructures through combined micromechanical testing and computational plasticity, and developing methods to generate solder joints with these microstructures by controlling the solidification process.
Collaborator Contribution Partners at the University of Greenwich are linking from the individual joint scale to the full component scale. This is being supported by a collaboration with Ford (USA) who are performing board-level reliability testing under harsh automotive thermal cycling conditions within the international electronics manufacturing initiative. Rolls-Royce are contributing to solder alloy selection studies as they move away from Sn-Pb solders in their applications that have benefitted from exemptions from Pb-free legislation. Together, we are working to improve solder joint reliability in emerging electronic applications.
Impact The intended outcomes are: To develop optimal microstructures for solder joint performance tailored to the specific demands of the application. For example, for an increase in operation temperature capability which can contribute to automotive/aerospace lightweighting by allowing shielding to be removed and electronics to be located closer to sensors with shorter wires, both of which save mass. In safety-critical applications, the critical loading differs significantly from potential impact and accident mitigation in the nuclear energy sector through to elevated temperature high cycle fatigue superimposed on low-cycle thermal cycling in the aero-engine industry.
Start Year 2018
 
Description EPSRC - High Reliability Interconnects: New Methodologies for Pb-free Solders 
Organisation Rolls Royce Group Plc
Department Rolls-Royce Naval Marine Inc
Country United States 
Sector Private 
PI Contribution Recently started (July 2018) EPSRC funded collaboration. We are working to develop a microstructurally-based predictive model of electronic solder joint behaviour during thermo-mechanical loading that links from the microstructure to the component scale. This involves identifying the optimum joint microstructures through combined micromechanical testing and computational plasticity, and developing methods to generate solder joints with these microstructures by controlling the solidification process.
Collaborator Contribution Partners at the University of Greenwich are linking from the individual joint scale to the full component scale. This is being supported by a collaboration with Ford (USA) who are performing board-level reliability testing under harsh automotive thermal cycling conditions within the international electronics manufacturing initiative. Rolls-Royce are contributing to solder alloy selection studies as they move away from Sn-Pb solders in their applications that have benefitted from exemptions from Pb-free legislation. Together, we are working to improve solder joint reliability in emerging electronic applications.
Impact The intended outcomes are: To develop optimal microstructures for solder joint performance tailored to the specific demands of the application. For example, for an increase in operation temperature capability which can contribute to automotive/aerospace lightweighting by allowing shielding to be removed and electronics to be located closer to sensors with shorter wires, both of which save mass. In safety-critical applications, the critical loading differs significantly from potential impact and accident mitigation in the nuclear energy sector through to elevated temperature high cycle fatigue superimposed on low-cycle thermal cycling in the aero-engine industry.
Start Year 2018
 
Description EPSRC - High Reliability Interconnects: New Methodologies for Pb-free Solders 
Organisation University of Greenwich
Country United Kingdom 
Sector Academic/University 
PI Contribution Recently started (July 2018) EPSRC funded collaboration. We are working to develop a microstructurally-based predictive model of electronic solder joint behaviour during thermo-mechanical loading that links from the microstructure to the component scale. This involves identifying the optimum joint microstructures through combined micromechanical testing and computational plasticity, and developing methods to generate solder joints with these microstructures by controlling the solidification process.
Collaborator Contribution Partners at the University of Greenwich are linking from the individual joint scale to the full component scale. This is being supported by a collaboration with Ford (USA) who are performing board-level reliability testing under harsh automotive thermal cycling conditions within the international electronics manufacturing initiative. Rolls-Royce are contributing to solder alloy selection studies as they move away from Sn-Pb solders in their applications that have benefitted from exemptions from Pb-free legislation. Together, we are working to improve solder joint reliability in emerging electronic applications.
Impact The intended outcomes are: To develop optimal microstructures for solder joint performance tailored to the specific demands of the application. For example, for an increase in operation temperature capability which can contribute to automotive/aerospace lightweighting by allowing shielding to be removed and electronics to be located closer to sensors with shorter wires, both of which save mass. In safety-critical applications, the critical loading differs significantly from potential impact and accident mitigation in the nuclear energy sector through to elevated temperature high cycle fatigue superimposed on low-cycle thermal cycling in the aero-engine industry.
Start Year 2018
 
Description EPSRC Constellium iCASE Studentship - David Makuyana 
Organisation Constellium
Department Constellium UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution Concerned with studies of the effect of processing parameters of melt conditioning during direct chill casting of Al 6xxx alloys on as-solidified microstructure and its contribution towards the development of microstructure and mechanical properties of aluminium extrusions.
Collaborator Contribution Constellium is focussed on the optimisation of the direct chill casting and hot extrusion processes at large scale for this project.
Impact Early stages of project.
Start Year 2018
 
Description EPSRC Constellium iCASE Studentship - David Makuyana 
Organisation Engineering and Physical Sciences Research Council (EPSRC)
Department EPSRC National Service for Solid State NMR
Country United Kingdom 
Sector Public 
PI Contribution Concerned with studies of the effect of processing parameters of melt conditioning during direct chill casting of Al 6xxx alloys on as-solidified microstructure and its contribution towards the development of microstructure and mechanical properties of aluminium extrusions.
Collaborator Contribution Constellium is focussed on the optimisation of the direct chill casting and hot extrusion processes at large scale for this project.
Impact Early stages of project.
Start Year 2018
 
Description EPSRC Constellium iCASE Studentship - Vincenzo De Stefano 
Organisation Constellium
Department Constellium UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution Work will examine advanced microscopy to understand the precipitate evolution and dislocation precipitate interactions in a class of ultra-high performance Al-alloys for automotive applications. It is expected that a fundamental understanding on interactions between dislocations and the precipitates, G P zones or solute clusters and their role in enhancing the strengthening observed in the thermo-mechanical approach developed by Constellium in a modified Al-Mg-Si alloy. As a part of the project the thermo mechanical approach developed by the industrial partner will be optimised.
Collaborator Contribution The industrial partner in addition to financial support will extrude the alloys as required to a number of different profiles. The student is exposured to Constellium's industrial practices and training and further supported with access to experimental techniques not available at Brunel University London.
Impact At present it is envisaged a number of high quality journal papers will be produced from the fundamental understanding developed as part of the work. The understanding coupled with lab scale optimisation will allow Constellium to optimise the approach within industrial constraints to further enhance the strength of the alloy. This will lead to increased applications for the alloy in question without a cost penalty and industrial partner is likely in the long run be able to replace a more expensive alloy with this alloy or break into new applications given the optimised property profile.
Start Year 2019
 
Description EPSRC Constellium iCASE Studentship - Vincenzo De Stefano 
Organisation Engineering and Physical Sciences Research Council (EPSRC)
Department EPSRC National Service for Solid State NMR
Country United Kingdom 
Sector Public 
PI Contribution Work will examine advanced microscopy to understand the precipitate evolution and dislocation precipitate interactions in a class of ultra-high performance Al-alloys for automotive applications. It is expected that a fundamental understanding on interactions between dislocations and the precipitates, G P zones or solute clusters and their role in enhancing the strengthening observed in the thermo-mechanical approach developed by Constellium in a modified Al-Mg-Si alloy. As a part of the project the thermo mechanical approach developed by the industrial partner will be optimised.
Collaborator Contribution The industrial partner in addition to financial support will extrude the alloys as required to a number of different profiles. The student is exposured to Constellium's industrial practices and training and further supported with access to experimental techniques not available at Brunel University London.
Impact At present it is envisaged a number of high quality journal papers will be produced from the fundamental understanding developed as part of the work. The understanding coupled with lab scale optimisation will allow Constellium to optimise the approach within industrial constraints to further enhance the strength of the alloy. This will lead to increased applications for the alloy in question without a cost penalty and industrial partner is likely in the long run be able to replace a more expensive alloy with this alloy or break into new applications given the optimised property profile.
Start Year 2019
 
Description EPSRC JLR iCASE Studentship - Ewan Lordan 
Organisation Engineering and Physical Sciences Research Council (EPSRC)
Country United Kingdom 
Sector Public 
PI Contribution Casting Integrity of High Pressure Die Castings. To establish a quantitative relationship between the casting integrity and the materials performance in tensile and fatigue, the research team has opted to take a combined experimental and simulation based approach. Melt filling and porosity potentials have been modeled in ProCAST with X-ray computed tomography used to analyse voids in the casting. This will enable the team to validate porosity predictions and ultimately predict fracture in the examined component.
Collaborator Contribution JLR hold regular meetings to steer the research to their industrial product requirements. Our contact from Jaguar Land Rover has provided invaluable input during each stage of the project, particularly in areas involving project management and technological integration within the business. This will ensure that outputs from the project will be beneficial to all partners.
Impact At present we have one publication pending in which our industrial partner is a co-author. Further outcomes will be recorded at the end of the project.
Start Year 2017
 
Description EPSRC JLR iCASE Studentship - Ewan Lordan 
Organisation Jaguar Land Rover Automotive PLC
Department Jaguar Land Rover
Country United Kingdom 
Sector Private 
PI Contribution Casting Integrity of High Pressure Die Castings. To establish a quantitative relationship between the casting integrity and the materials performance in tensile and fatigue, the research team has opted to take a combined experimental and simulation based approach. Melt filling and porosity potentials have been modeled in ProCAST with X-ray computed tomography used to analyse voids in the casting. This will enable the team to validate porosity predictions and ultimately predict fracture in the examined component.
Collaborator Contribution JLR hold regular meetings to steer the research to their industrial product requirements. Our contact from Jaguar Land Rover has provided invaluable input during each stage of the project, particularly in areas involving project management and technological integration within the business. This will ensure that outputs from the project will be beneficial to all partners.
Impact At present we have one publication pending in which our industrial partner is a co-author. Further outcomes will be recorded at the end of the project.
Start Year 2017
 
Description EPSRC JLR iCASE studentship - Hamza Youssef 
Organisation Jaguar Land Rover Automotive PLC
Department Jaguar Land Rover
Country United Kingdom 
Sector Private 
PI Contribution EPSRC and JLR iCASE studentship investigating the manufacturing of high integrity castings.
Collaborator Contribution Development and guidance in line with product requirements.
Impact Early stages of the PhD and results are still a work in progress.
Start Year 2018
 
Description EPSRC and Constellium - iCASE studentship Chrysoula Tzileroglou 
Organisation Constellium
Country France 
Sector Private 
PI Contribution Novel processing of 6xxx alloys for automotive applications - iCASE Studentship, Chrysoula Tzileroglou. This collaboration involves the understanding and optimisation of the processing (e.g. extrusion, post thermomechanical treatments) conditions on microstructure and mechanical performance in terms of hardness, yield strength, tensile strength and ductility.
Collaborator Contribution Constellium hold regular meetings to steer the research to their industrial product requirements. Constellium: (a) provision of DC billets and extrusions of HSA8 alloys. Regular technical review meeting and workshop training organised by Constellium staff members. (b) Provision of research strategy and direction relevant to their business.
Impact Outcomes to date have included: Studied the effect of extrusion parameters, post heat treatment conditions on mechanical performance of HSA6 alloys, as well as the influence of extrusion die geometry on the fibrous texture in the extruded microstructure prior to strain enhanced precipitation treatment.
Start Year 2017
 
Description EPSRC and Constellium - iCASE studentship Chrysoula Tzileroglou 
Organisation Engineering and Physical Sciences Research Council (EPSRC)
Country United Kingdom 
Sector Public 
PI Contribution Novel processing of 6xxx alloys for automotive applications - iCASE Studentship, Chrysoula Tzileroglou. This collaboration involves the understanding and optimisation of the processing (e.g. extrusion, post thermomechanical treatments) conditions on microstructure and mechanical performance in terms of hardness, yield strength, tensile strength and ductility.
Collaborator Contribution Constellium hold regular meetings to steer the research to their industrial product requirements. Constellium: (a) provision of DC billets and extrusions of HSA8 alloys. Regular technical review meeting and workshop training organised by Constellium staff members. (b) Provision of research strategy and direction relevant to their business.
Impact Outcomes to date have included: Studied the effect of extrusion parameters, post heat treatment conditions on mechanical performance of HSA6 alloys, as well as the influence of extrusion die geometry on the fibrous texture in the extruded microstructure prior to strain enhanced precipitation treatment.
Start Year 2017
 
Description Feasibility for the direct in-situ observation of solidification at the meso-scale and the study of nucleation and grain growth competition 
Organisation University of Warwick
Country United Kingdom 
Sector Academic/University 
PI Contribution Award is £37,480 (£29,984 at 80% FEC)
Collaborator Contribution Award is £37,480 (£29,984 at 80% FEC) given by LiME Hub to University of Warwick.
Impact The project aim is to design, fabricate and test a new approach for direct observation of solidification to allow characterisation at the meso-scale, i.e. over a microstructurally significant area (approximately 3 by 3 mm) by extending the capability of the confocal laser scanning microscope (CLSM) and including simultaneous IR thermography and demonstrating the new scientific understanding this can offer.
Start Year 2020
 
Description Federal-Mogul Powertrain 
Organisation Federal Mogul
Country United States 
Sector Private 
PI Contribution Conducted a planned trial of HSMC technology. The HSMC technology possesses the characteristics of both distributive and dispersive mixing, hence the motivation behind this trial was to improve the size and distribution of the Sn-phase, together with the rest of the advantages of intensive melt shearing. This trial, currently at the design stage, focuses on the HSMC technology and its implementation and integration into the existing launder system that feeds the twin roll caster, instead of the two holding furnaces, to avoid the challenge of scaling up the HSMC equipment and to apply intensive melt shearing as close as possible to the twin rolls, for better preservation and solidification of the Sn-phase.
Collaborator Contribution Information in relation to the current processes and and issues are provided, along with the use of their facilities once the designed trial is ready to be implemented.
Impact Trials to be conducted.
Start Year 2017
 
Description Frech GmbH + Co 
Organisation Oskar Frech GmbH + Co. KG
Country Germany 
Sector Private 
PI Contribution Collaboration in relation to the AMCC.
Collaborator Contribution Suppliers of the high pressure die casting machine at the AMCC. Presented a pair of interlinked, polished piston rings symbolising the working relationship between Frech and BCAST.
Impact Promotes the positive international relationship between academia and a lead international equipment supplier.
Start Year 2016
 
Description Fundamental study on FFC behavior of aluminium alloys 
Organisation Novelis
Country United States 
Sector Private 
PI Contribution Intellectual output and conducted research of microstructure/property relationship by research of full time PhD student conducting dedicated research over life of project
Collaborator Contribution Provide samples, materials, direct PhD student support and development, industrial expertise.
Impact still recruiting to post
Start Year 2022
 
Description Grain Refiner - Industry testing 
Organisation Beta Technology Ltd
Country United Kingdom 
Sector Private 
PI Contribution Sponsor developed industrial scale processing of Al-Nb-B master alloy. Grain refinement performance is tested at Brunel under laboratory conditions.
Collaborator Contribution Grainger and Worrall tested the alloy at industrial scale, investigating the integrity of castings in detail, with the tensile properties measured and tested in HPDC conditions. Currently the multiple characteristics of the master alloy are being evaluated.
Impact CBMM developed and produced Al-Nb-B master alloy in a pilot-scale in Brazil, supporting Brunel in analysing chemical composition using ICP analysis, CBMM also producing industrial scale (1 tonne/batch) master alloy at Norton Aluminium. This master alloy has been used by end-users and foundries.
Start Year 2016
 
Description Grain Refiner - Industry testing 
Organisation CBMM Technology Suisse
Country Switzerland 
Sector Private 
PI Contribution Sponsor developed industrial scale processing of Al-Nb-B master alloy. Grain refinement performance is tested at Brunel under laboratory conditions.
Collaborator Contribution Grainger and Worrall tested the alloy at industrial scale, investigating the integrity of castings in detail, with the tensile properties measured and tested in HPDC conditions. Currently the multiple characteristics of the master alloy are being evaluated.
Impact CBMM developed and produced Al-Nb-B master alloy in a pilot-scale in Brazil, supporting Brunel in analysing chemical composition using ICP analysis, CBMM also producing industrial scale (1 tonne/batch) master alloy at Norton Aluminium. This master alloy has been used by end-users and foundries.
Start Year 2016
 
Description Grain Refiner - Industry testing 
Organisation Grainger & Worrall Limited
Country United Kingdom 
Sector Private 
PI Contribution Sponsor developed industrial scale processing of Al-Nb-B master alloy. Grain refinement performance is tested at Brunel under laboratory conditions.
Collaborator Contribution Grainger and Worrall tested the alloy at industrial scale, investigating the integrity of castings in detail, with the tensile properties measured and tested in HPDC conditions. Currently the multiple characteristics of the master alloy are being evaluated.
Impact CBMM developed and produced Al-Nb-B master alloy in a pilot-scale in Brazil, supporting Brunel in analysing chemical composition using ICP analysis, CBMM also producing industrial scale (1 tonne/batch) master alloy at Norton Aluminium. This master alloy has been used by end-users and foundries.
Start Year 2016
 
Description Grain refinement of Pure Cu using a Novel Contactless Ultrasound Technique 
Organisation University of Birmingham
Country United Kingdom 
Sector Academic/University 
PI Contribution LiME Hub has given an award for£37,477.60 at 100% FEC (£29,982.10 at 80% FEC).
Collaborator Contribution Award for £37,477.60 at 100% FEC (£29,982.10 at 80% FEC) - Advice available from LiME members and project partners.
Impact The feasibility study described here strongly contributes to one of the overall directions of the Hub research, namely, the study of nucleation-centred solidification science, and specifically supports the research priority aimed at maintaining properties after recycling.
Start Year 2020
 
Description Heterogeneous nucleation and grain refinement in an Al-Fe-Cr-Ti alloy by controlled laser and electron beam remelting 
Organisation Loughborough University
Country United Kingdom 
Sector Academic/University 
PI Contribution Award is £29997.26 at 80% FEC (£37496.57 at 100% FEC)
Collaborator Contribution Award is £29997.26 at 80% FEC (£37496.57 at 100% FEC) given by LiME Hub to Loughborough University.
Impact This feasibility study aims to build a research partnership between Dr. Simon Hogg (SH) at Loughborough University (LU) and Dr. Katy Voisey (KV) at The University of Nottingham (UoN) to perform fundamental research into heterogeneous nucleation of a fine-grained microstructure using controlled, localised surface laser and e-beam remelting. The chosen Al-Fe-Cr-Ti alloy contains a significant impurity content and the research may additionally inform strategies for recovery and recycling of highly impure alloys.
Start Year 2020
 
Description Husqvarna - Advanced magnesium piston development 
Organisation Husqvarna Group
Country Sweden 
Sector Private 
PI Contribution We have successfully developed a novel magnesium alloy for making pistons in small petrol engines, which can be used in chainsaws and other such products.The main contributions include (1) alloy design for purpose used magnesium materials, (2) casting development of piston using high pressure die casting, and (3) materials characterisation for high temperature alloys.
Collaborator Contribution Husqvarna provide guidance and development on the piston requirements and application.
Impact This work is multiple disciplinary, including thermodynamic(s) assessment of each element in magnesium alloys, alloy design and casting practice and materials analysis. So there is not only theoretical development for high temperature Mg alloys, but also the break through in real industrial applications.
Start Year 2018
 
Description IOM3 
Organisation The Institute of Materials, Minerals and Mining
Country United Kingdom 
Sector Charity/Non Profit 
PI Contribution In-kind - Dr Simon Butler is the chair of the Casting and Solidification Division, succeeding Prof Fan.
Collaborator Contribution Sponsors of the John Hunt Medal and Memorial Lecture
Impact Ongoing.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Aeromet International
Country United Kingdom 
Sector Private 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Cast Metals Federation
Country United Kingdom 
Sector Charity/Non Profit 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Constellium
Department Constellium UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Gordon Murray Design Ltd
Country United Kingdom 
Sector Private 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Grainger & Worrall Limited
Country United Kingdom 
Sector Private 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Innoval Technology
Country United Kingdom 
Sector Private 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Jaguar Land Rover Automotive PLC
Department Jaguar Land Rover
Country United Kingdom 
Sector Private 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation National Physical Laboratory
Department Radiation Dosimetry
Country United Kingdom 
Sector Academic/University 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Nissan Motor Manufacturing Ltd
Country United Kingdom 
Sector Private 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Norton Aluminium Ltd
Country United Kingdom 
Sector Private 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Sarginsons Industries Ltd
Country United Kingdom 
Sector Private 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Stone Foundries Ltd
Country United Kingdom 
Sector Academic/University 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Steering Panel - ISP 
Organisation Weir Group plc
Country United Kingdom 
Sector Private 
PI Contribution Presentation of research and developments in an industrially appropriate manner to update the board of the programmes progress.
Collaborator Contribution Panel provides feedback and steering of research to ensure its alignment with industrial requirements.
Impact A large number of outputs, best summed up via the actions and summaries in the ISP minutes.
Start Year 2015
 
Description Industrial Trial - Apple 
Organisation Apple
Country United States 
Sector Private 
PI Contribution Investigation was performed on three specially selected Apple Inc. Al-alloys to evaluate the effect of MC-DC casting and more importantly to access the benefits of not using commercial grain refiner (Al-Ti-B type) during casting. These MC-DC trials were conducted at the AMCC and produced billets for Apple.
Collaborator Contribution The billets were shipped to Apple for extrusion into thin profiles and subsequent analysis in terms of microstructural and chemical segregation integrity, especially surface finish after extrusion with the ambition of eliminating surface streak marks which are known to be caused by addition of Al-Ti-B based grain refiners.
Impact Billets of 6inch diameter and 2 metre lengths were cast at the most optimised parameters. Further outcomes/conclusions are confidential.
Start Year 2016
 
Description Innovate UK - APC 6 - CHAMAELEON 
Organisation GKN
Department GKN Aerospace
Country United Kingdom 
Sector Private 
PI Contribution Through utilising our facilities to supply the castings required for further treatment as defined by the partners.
Collaborator Contribution Specifications are supplied from the collaborators in relation to the casting structure and requirements for the industrial components. Project partners carry out further treatments on the castings.
Impact There has been a good output so far in relation to the HPDC casting for a specially designed casting alloy to enable the analysis of the fluidity of such alloys under HPDC.
Start Year 2017
 
Description Innovate UK - APC 6 - CHAMAELEON 
Organisation Jaguar Land Rover Automotive PLC
Department Jaguar Land Rover
Country United Kingdom 
Sector Private 
PI Contribution Through utilising our facilities to supply the castings required for further treatment as defined by the partners.
Collaborator Contribution Specifications are supplied from the collaborators in relation to the casting structure and requirements for the industrial components. Project partners carry out further treatments on the castings.
Impact There has been a good output so far in relation to the HPDC casting for a specially designed casting alloy to enable the analysis of the fluidity of such alloys under HPDC.
Start Year 2017
 
Description Innovate UK - APC 6 - CHAMAELEON 
Organisation Magna International
Country Canada 
Sector Private 
PI Contribution Through utilising our facilities to supply the castings required for further treatment as defined by the partners.
Collaborator Contribution Specifications are supplied from the collaborators in relation to the casting structure and requirements for the industrial components. Project partners carry out further treatments on the castings.
Impact There has been a good output so far in relation to the HPDC casting for a specially designed casting alloy to enable the analysis of the fluidity of such alloys under HPDC.
Start Year 2017
 
Description Innovate UK - APC 6 - CHAMAELEON 
Organisation Powdertech
Country United Kingdom 
Sector Private 
PI Contribution Through utilising our facilities to supply the castings required for further treatment as defined by the partners.
Collaborator Contribution Specifications are supplied from the collaborators in relation to the casting structure and requirements for the industrial components. Project partners carry out further treatments on the castings.
Impact There has been a good output so far in relation to the HPDC casting for a specially designed casting alloy to enable the analysis of the fluidity of such alloys under HPDC.
Start Year 2017
 
Description Innovate UK - APC 6 - CHAMAELEON 
Organisation University of Warwick
Department University of Warwick Research Students Skills Programme
Country United Kingdom 
Sector Academic/University 
PI Contribution Through utilising our facilities to supply the castings required for further treatment as defined by the partners.
Collaborator Contribution Specifications are supplied from the collaborators in relation to the casting structure and requirements for the industrial components. Project partners carry out further treatments on the castings.
Impact There has been a good output so far in relation to the HPDC casting for a specially designed casting alloy to enable the analysis of the fluidity of such alloys under HPDC.
Start Year 2017
 
Description Innovate UK - Advanced Propulsion Centre (APC) Wave 7: RACEForm 
Organisation Autotech Engineering R&D UK Limited
Country United Kingdom 
Sector Private 
PI Contribution Innovate UK funded. RACEForm project is designed to catalyse cost-effective light-weighting of high volume vehicle platforms using a robust UK supply chain. BCAST contributes through the investigation into the use of low cost impure alloys (high recycled content), and the fixing and welding methods for assembly of Hot Form Quench (HFQ®) parts in lab scale testing environments.
Collaborator Contribution The enabling technology, Hot Form Quench HFQ® was developed in Imperial College & the University of Birmingham and has a unique capability to produce, at high speed, complex high-strength aluminium components for body-in-white & chassis applications. The RACEForm projects takes this unique technology, proven for niche vehicle applications, through to a readiness for application in high volume SUV & electric vehicles by combining the expertise of Impression Technologies (who own the HFQ® technology), Gestamp (a global leader in automotive stampings), Innoval (a leading aluminium technology consulting company), Imperial College & Brunel University. The project will aim to reduce production cost via cycle time improvements, validate joining & crash performance & even develop an approach for utilising recycled aluminium for critical structural components delivering lower CO2 emissions, embedded carbon content of the vehicle, production cost & (via weight savings) range/performance of electric versions of platforms.
Impact Presentation of Microstructural investigation of high strength self-piercing riveted joints of different car body aluminium alloys at PFAMXXVII - Processing and Fabrication of Advanced Materials on 27-29 May 2019 at Jönköping, Sweden. Further outcomes to be detailed on project completion. The project will aim to reduce production cost via cycle time improvements, validate joining & crash performance & even develop an approach for utilising recycled aluminium for critical structural components delivering lower CO2 emissions, embedded carbon content of the vehicle, production cost & (via weight savings) range/performance of electric versions of platforms.
Start Year 2017
 
Description Innovate UK - Advanced Propulsion Centre (APC) Wave 7: RACEForm 
Organisation Imperial College London
Country United Kingdom 
Sector Academic/University 
PI Contribution Innovate UK funded. RACEForm project is designed to catalyse cost-effective light-weighting of high volume vehicle platforms using a robust UK supply chain. BCAST contributes through the investigation into the use of low cost impure alloys (high recycled content), and the fixing and welding methods for assembly of Hot Form Quench (HFQ®) parts in lab scale testing environments.
Collaborator Contribution The enabling technology, Hot Form Quench HFQ® was developed in Imperial College & the University of Birmingham and has a unique capability to produce, at high speed, complex high-strength aluminium components for body-in-white & chassis applications. The RACEForm projects takes this unique technology, proven for niche vehicle applications, through to a readiness for application in high volume SUV & electric vehicles by combining the expertise of Impression Technologies (who own the HFQ® technology), Gestamp (a global leader in automotive stampings), Innoval (a leading aluminium technology consulting company), Imperial College & Brunel University. The project will aim to reduce production cost via cycle time improvements, validate joining & crash performance & even develop an approach for utilising recycled aluminium for critical structural components delivering lower CO2 emissions, embedded carbon content of the vehicle, production cost & (via weight savings) range/performance of electric versions of platforms.
Impact Presentation of Microstructural investigation of high strength self-piercing riveted joints of different car body aluminium alloys at PFAMXXVII - Processing and Fabrication of Advanced Materials on 27-29 May 2019 at Jönköping, Sweden. Further outcomes to be detailed on project completion. The project will aim to reduce production cost via cycle time improvements, validate joining & crash performance & even develop an approach for utilising recycled aluminium for critical structural components delivering lower CO2 emissions, embedded carbon content of the vehicle, production cost & (via weight savings) range/performance of electric versions of platforms.
Start Year 2017
 
Description Innovate UK - Advanced Propulsion Centre (APC) Wave 7: RACEForm 
Organisation Impression Technologies Ltd
Country United Kingdom 
Sector Private 
PI Contribution Innovate UK funded. RACEForm project is designed to catalyse cost-effective light-weighting of high volume vehicle platforms using a robust UK supply chain. BCAST contributes through the investigation into the use of low cost impure alloys (high recycled content), and the fixing and welding methods for assembly of Hot Form Quench (HFQ®) parts in lab scale testing environments.
Collaborator Contribution The enabling technology, Hot Form Quench HFQ® was developed in Imperial College & the University of Birmingham and has a unique capability to produce, at high speed, complex high-strength aluminium components for body-in-white & chassis applications. The RACEForm projects takes this unique technology, proven for niche vehicle applications, through to a readiness for application in high volume SUV & electric vehicles by combining the expertise of Impression Technologies (who own the HFQ® technology), Gestamp (a global leader in automotive stampings), Innoval (a leading aluminium technology consulting company), Imperial College & Brunel University. The project will aim to reduce production cost via cycle time improvements, validate joining & crash performance & even develop an approach for utilising recycled aluminium for critical structural components delivering lower CO2 emissions, embedded carbon content of the vehicle, production cost & (via weight savings) range/performance of electric versions of platforms.
Impact Presentation of Microstructural investigation of high strength self-piercing riveted joints of different car body aluminium alloys at PFAMXXVII - Processing and Fabrication of Advanced Materials on 27-29 May 2019 at Jönköping, Sweden. Further outcomes to be detailed on project completion. The project will aim to reduce production cost via cycle time improvements, validate joining & crash performance & even develop an approach for utilising recycled aluminium for critical structural components delivering lower CO2 emissions, embedded carbon content of the vehicle, production cost & (via weight savings) range/performance of electric versions of platforms.
Start Year 2017
 
Description Innovate UK - Advanced Propulsion Centre (APC) Wave 7: RACEForm 
Organisation Innoval Technology
Country United Kingdom 
Sector Private 
PI Contribution Innovate UK funded. RACEForm project is designed to catalyse cost-effective light-weighting of high volume vehicle platforms using a robust UK supply chain. BCAST contributes through the investigation into the use of low cost impure alloys (high recycled content), and the fixing and welding methods for assembly of Hot Form Quench (HFQ®) parts in lab scale testing environments.
Collaborator Contribution The enabling technology, Hot Form Quench HFQ® was developed in Imperial College & the University of Birmingham and has a unique capability to produce, at high speed, complex high-strength aluminium components for body-in-white & chassis applications. The RACEForm projects takes this unique technology, proven for niche vehicle applications, through to a readiness for application in high volume SUV & electric vehicles by combining the expertise of Impression Technologies (who own the HFQ® technology), Gestamp (a global leader in automotive stampings), Innoval (a leading aluminium technology consulting company), Imperial College & Brunel University. The project will aim to reduce production cost via cycle time improvements, validate joining & crash performance & even develop an approach for utilising recycled aluminium for critical structural components delivering lower CO2 emissions, embedded carbon content of the vehicle, production cost & (via weight savings) range/performance of electric versions of platforms.
Impact Presentation of Microstructural investigation of high strength self-piercing riveted joints of different car body aluminium alloys at PFAMXXVII - Processing and Fabrication of Advanced Materials on 27-29 May 2019 at Jönköping, Sweden. Further outcomes to be detailed on project completion. The project will aim to reduce production cost via cycle time improvements, validate joining & crash performance & even develop an approach for utilising recycled aluminium for critical structural components delivering lower CO2 emissions, embedded carbon content of the vehicle, production cost & (via weight savings) range/performance of electric versions of platforms.
Start Year 2017
 
Description Innovate UK - Aluminium Reduced Cost Hybrid Parts (ARCH) 
Organisation Autotech Engineering R&D UK Limited
Country United Kingdom 
Sector Private 
PI Contribution The ARCH project seeks to develop a novel fabricated-hybrid-chassis structure to replace the state-of-the-art steel chassis structures currently used extensively for the automobile industry. Driven by the concept of "right materials in the right places", a mixture of aluminium extruded and cast node parts are incorporated into the design of the fabricated-chassis-hybrid structure to deliver weight savings of over 30% when compared with the equivalent conventional steel systems. Within the automotive industry, accurate predictive performance analysis using CAE tools is key to eliminating potential failure without the need for multiple testing loops and correlation. As the industry is moving away from producing prototype parts prior to serial production, the predictive design capabilities will be developed within the project, enabling the formulation of reliable digital design tools to accurately predict the performance, durability and failure of fabricated-chassis-hybrid alloy structures in chassis applications Another critical part of the project is the development of a reliable, robust and cost effective manufacturing process since rapid, repeatable and productive processes are key to accelerating the use of high strength fabricated-chassis-hybrid alloy structures for mass production vehicles.
Collaborator Contribution A candidate for the technology will be developed in multiple design iterations, then optimised and demonstrated with the production of full-size chassis components and the performance of the demonstrator systems will be evaluated against relevant benchmarks. Physical test data will enable the validation of the newly formulated predictive design tools.
Impact In the early stages of the project and outcomes are to be updated.
Start Year 2018
 
Description Innovate UK - Aluminium for Ultra Low Emission Vehicles (Al-ULEV) 
Organisation Constellium
Department Constellium UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution The main objectives of the project are to provide high strength extruded components for the manufacture of vehicle frames and battery enclosures for GMD i-Stream and JLR I-Pace electric vehicles.
Collaborator Contribution The first generation of vehicle and enclosure extruded components will use the present Constellium HSA6 and HCA6 aluminium extrusion alloys to provide component weight saving beyond the current state-of-the art.
Impact The project will design, develop extruded components for prototype vehicle integration systems and for battery enclosures for Gordon Murray Design for an electric vehicle based on the aluminium intensive version of their i-Stream vehicle under development in the IUK CAAHS project. The second development in the project will be for vehicle integration and battery box enclosures, for the JLR I-Pace. The longer term intention is to establish a UK based manufacturing facility for world leading cost efficient aluminium extruded sections based on the intensive use of fully recyclable aluminium alloys in order to provide an on-shore resource for both extrusion and ULEV component manufacture.
Start Year 2018
 
Description Innovate UK - Aluminium for Ultra Low Emission Vehicles (Al-ULEV) 
Organisation Gordon Murray Design Ltd
Country United Kingdom 
Sector Private 
PI Contribution The main objectives of the project are to provide high strength extruded components for the manufacture of vehicle frames and battery enclosures for GMD i-Stream and JLR I-Pace electric vehicles.
Collaborator Contribution The first generation of vehicle and enclosure extruded components will use the present Constellium HSA6 and HCA6 aluminium extrusion alloys to provide component weight saving beyond the current state-of-the art.
Impact The project will design, develop extruded components for prototype vehicle integration systems and for battery enclosures for Gordon Murray Design for an electric vehicle based on the aluminium intensive version of their i-Stream vehicle under development in the IUK CAAHS project. The second development in the project will be for vehicle integration and battery box enclosures, for the JLR I-Pace. The longer term intention is to establish a UK based manufacturing facility for world leading cost efficient aluminium extruded sections based on the intensive use of fully recyclable aluminium alloys in order to provide an on-shore resource for both extrusion and ULEV component manufacture.
Start Year 2018
 
Description Innovate UK - Aluminium for Ultra Low Emission Vehicles (Al-ULEV) 
Organisation Innoval Technology
Country United Kingdom 
Sector Private 
PI Contribution The main objectives of the project are to provide high strength extruded components for the manufacture of vehicle frames and battery enclosures for GMD i-Stream and JLR I-Pace electric vehicles.
Collaborator Contribution The first generation of vehicle and enclosure extruded components will use the present Constellium HSA6 and HCA6 aluminium extrusion alloys to provide component weight saving beyond the current state-of-the art.
Impact The project will design, develop extruded components for prototype vehicle integration systems and for battery enclosures for Gordon Murray Design for an electric vehicle based on the aluminium intensive version of their i-Stream vehicle under development in the IUK CAAHS project. The second development in the project will be for vehicle integration and battery box enclosures, for the JLR I-Pace. The longer term intention is to establish a UK based manufacturing facility for world leading cost efficient aluminium extruded sections based on the intensive use of fully recyclable aluminium alloys in order to provide an on-shore resource for both extrusion and ULEV component manufacture.
Start Year 2018
 
Description Innovate UK - Carbon Aluminium Automotive Hybrid Structures (CAAHS) 
Organisation Bentley Motors
Country United Kingdom 
Sector Private 
PI Contribution The project consortium of Gordon Murray Design, Innoval Technology Limited, Constellium and Brunel University (BCAST) aim to develop an iStream monocoque that is 30 - 40% lighter than the incumbent steel/glass fibre composite structure. Using a novel high strength extrusion alloy combined with advanced composite panels based on recycled carbon fibre, the project aims to further reduce CO2 emissions through significant lightweighting, whilst maintaining the high volume, low cost benefits of the original disruptive iStream technology. BCAST provided the forming and joining techniques at the AMCC and AMPC.
Collaborator Contribution Gordon Murray Design's innovative and ground breaking iStream automotive manufacturing technology allows significant reductions in setup, production costs, vehicle mass, and lifecycle CO2 emissions, whilst offering cost effective design flexibility that exceeds current Euro NCAP occupant and pedestrian impact regulations. The project aims to take another major step, making full use of the iStream process, towards a new generation of lightweight vehicles for the UK market that can have a major impact on the UK government's carbon reduction targets for the UK vehicle fleet.
Impact In total, two new frames were completed and manufactured; one to undergo crash tests to assess performance and the second kept intact for showcasing at public events. The new iStream® structure that resulted was inherently recyclable and provided a development path for future weight reduction in body, chassis and power train systems through the development of higher strength recyclable aluminium alloys and enabling joining technologies.
Start Year 2016
 
Description Innovate UK - Carbon Aluminium Automotive Hybrid Structures (CAAHS) 
Organisation Constellium
Department Constellium UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution The project consortium of Gordon Murray Design, Innoval Technology Limited, Constellium and Brunel University (BCAST) aim to develop an iStream monocoque that is 30 - 40% lighter than the incumbent steel/glass fibre composite structure. Using a novel high strength extrusion alloy combined with advanced composite panels based on recycled carbon fibre, the project aims to further reduce CO2 emissions through significant lightweighting, whilst maintaining the high volume, low cost benefits of the original disruptive iStream technology. BCAST provided the forming and joining techniques at the AMCC and AMPC.
Collaborator Contribution Gordon Murray Design's innovative and ground breaking iStream automotive manufacturing technology allows significant reductions in setup, production costs, vehicle mass, and lifecycle CO2 emissions, whilst offering cost effective design flexibility that exceeds current Euro NCAP occupant and pedestrian impact regulations. The project aims to take another major step, making full use of the iStream process, towards a new generation of lightweight vehicles for the UK market that can have a major impact on the UK government's carbon reduction targets for the UK vehicle fleet.
Impact In total, two new frames were completed and manufactured; one to undergo crash tests to assess performance and the second kept intact for showcasing at public events. The new iStream® structure that resulted was inherently recyclable and provided a development path for future weight reduction in body, chassis and power train systems through the development of higher strength recyclable aluminium alloys and enabling joining technologies.
Start Year 2016
 
Description Innovate UK - Carbon Aluminium Automotive Hybrid Structures (CAAHS) 
Organisation Gordon Murray Design Ltd
Country United Kingdom 
Sector Private 
PI Contribution The project consortium of Gordon Murray Design, Innoval Technology Limited, Constellium and Brunel University (BCAST) aim to develop an iStream monocoque that is 30 - 40% lighter than the incumbent steel/glass fibre composite structure. Using a novel high strength extrusion alloy combined with advanced composite panels based on recycled carbon fibre, the project aims to further reduce CO2 emissions through significant lightweighting, whilst maintaining the high volume, low cost benefits of the original disruptive iStream technology. BCAST provided the forming and joining techniques at the AMCC and AMPC.
Collaborator Contribution Gordon Murray Design's innovative and ground breaking iStream automotive manufacturing technology allows significant reductions in setup, production costs, vehicle mass, and lifecycle CO2 emissions, whilst offering cost effective design flexibility that exceeds current Euro NCAP occupant and pedestrian impact regulations. The project aims to take another major step, making full use of the iStream process, towards a new generation of lightweight vehicles for the UK market that can have a major impact on the UK government's carbon reduction targets for the UK vehicle fleet.
Impact In total, two new frames were completed and manufactured; one to undergo crash tests to assess performance and the second kept intact for showcasing at public events. The new iStream® structure that resulted was inherently recyclable and provided a development path for future weight reduction in body, chassis and power train systems through the development of higher strength recyclable aluminium alloys and enabling joining technologies.
Start Year 2016
 
Description Innovate UK - Carbon Aluminium Automotive Hybrid Structures (CAAHS) 
Organisation Innoval Technology
Country United Kingdom 
Sector Private 
PI Contribution The project consortium of Gordon Murray Design, Innoval Technology Limited, Constellium and Brunel University (BCAST) aim to develop an iStream monocoque that is 30 - 40% lighter than the incumbent steel/glass fibre composite structure. Using a novel high strength extrusion alloy combined with advanced composite panels based on recycled carbon fibre, the project aims to further reduce CO2 emissions through significant lightweighting, whilst maintaining the high volume, low cost benefits of the original disruptive iStream technology. BCAST provided the forming and joining techniques at the AMCC and AMPC.
Collaborator Contribution Gordon Murray Design's innovative and ground breaking iStream automotive manufacturing technology allows significant reductions in setup, production costs, vehicle mass, and lifecycle CO2 emissions, whilst offering cost effective design flexibility that exceeds current Euro NCAP occupant and pedestrian impact regulations. The project aims to take another major step, making full use of the iStream process, towards a new generation of lightweight vehicles for the UK market that can have a major impact on the UK government's carbon reduction targets for the UK vehicle fleet.
Impact In total, two new frames were completed and manufactured; one to undergo crash tests to assess performance and the second kept intact for showcasing at public events. The new iStream® structure that resulted was inherently recyclable and provided a development path for future weight reduction in body, chassis and power train systems through the development of higher strength recyclable aluminium alloys and enabling joining technologies.
Start Year 2016
 
Description Innovate UK - Lightweighting Children's Bikes 
Organisation Constellium
Department Constellium UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution Light-weighting Children's Bikes - examines the technical feasibility of a novel aluminium alloy to produce a lighter bike to make it easier for children to learn to ride. Creating a light yet strong aluminium frame.
Collaborator Contribution Development and guidance in accordance with predefined parameters.
Impact Potential patent to be submitted once the project has concluded.
Start Year 2017
 
Description Innovate UK - Lightweighting Children's Bikes 
Organisation Frog Bikes Limited
Country United Kingdom 
Sector Private 
PI Contribution Light-weighting Children's Bikes - examines the technical feasibility of a novel aluminium alloy to produce a lighter bike to make it easier for children to learn to ride. Creating a light yet strong aluminium frame.
Collaborator Contribution Development and guidance in accordance with predefined parameters.
Impact Potential patent to be submitted once the project has concluded.
Start Year 2017
 
Description Integrated Computational Process Engineering with focus on Aluminium Extrusion - Ross Jarrett 
Organisation Constellium
Department Constellium UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution After several meetings deciding what computational resources to utilise for the project, it was concluded there were many instances where decisions were being made in suboptimal fashion in many other projects. Therefore, as a first step, there is a focus universally on the initial stage of this project, with the aim of creating an intelligent/expert system to aid in the decision making process.
Collaborator Contribution Members of the Constellium technical team continue to assist with the direct application of the proposed expert system. This ensures to a good alignment with a real-world, industrial setting/application.
Impact The field is indeed multi-disciplinary; combining personnel from the fields of AI/machine learning, computational metallurgy, as well as general engineering/materials science. The project has taken a little time time to find a solid direction and as such the resultant outputs will be tangible in due course. One main output will be a useable system (computer application) that myriad project creators can use as a technical, decision-making tool.
Start Year 2018
 
Description Integrated Computational Process Engineering with focus on Aluminium Extrusion - Ross Jarrett 
Organisation Engineering and Physical Sciences Research Council (EPSRC)
Country United Kingdom 
Sector Public 
PI Contribution After several meetings deciding what computational resources to utilise for the project, it was concluded there were many instances where decisions were being made in suboptimal fashion in many other projects. Therefore, as a first step, there is a focus universally on the initial stage of this project, with the aim of creating an intelligent/expert system to aid in the decision making process.
Collaborator Contribution Members of the Constellium technical team continue to assist with the direct application of the proposed expert system. This ensures to a good alignment with a real-world, industrial setting/application.
Impact The field is indeed multi-disciplinary; combining personnel from the fields of AI/machine learning, computational metallurgy, as well as general engineering/materials science. The project has taken a little time time to find a solid direction and as such the resultant outputs will be tangible in due course. One main output will be a useable system (computer application) that myriad project creators can use as a technical, decision-making tool.
Start Year 2018
 
Description International Advisory Board, IAB 
Organisation German Aerospace Centre (DLR)
Department DLR Institute Of Planetary Research
Country Germany 
Sector Academic/University 
PI Contribution Scientific presentation of the current research and developments to the panel for review.
Collaborator Contribution Reviews and discusses developments and makes suggestions for the future direction of research, outreach and industrial related engagement.
Impact Numerous outputs and actions, best summarised in the actions and summaries in the IAB minutes.
Start Year 2015
 
Description International Advisory Board, IAB 
Organisation Helmholtz Association of German Research Centres
Department Helmholtz-Zentrum Geesthacht
Country Germany 
Sector Academic/University 
PI Contribution Scientific presentation of the current research and developments to the panel for review.
Collaborator Contribution Reviews and discusses developments and makes suggestions for the future direction of research, outreach and industrial related engagement.
Impact Numerous outputs and actions, best summarised in the actions and summaries in the IAB minutes.
Start Year 2015
 
Description International Advisory Board, IAB 
Organisation Norwegian University of Science and Technology (NTNU)
Country Norway 
Sector Academic/University 
PI Contribution Scientific presentation of the current research and developments to the panel for review.
Collaborator Contribution Reviews and discusses developments and makes suggestions for the future direction of research, outreach and industrial related engagement.
Impact Numerous outputs and actions, best summarised in the actions and summaries in the IAB minutes.
Start Year 2015
 
Description International Advisory Board, IAB 
Organisation Swiss Federal Institute of Technology in Lausanne (EPFL)
Department Global Health Institute
Country Switzerland 
Sector Academic/University 
PI Contribution Scientific presentation of the current research and developments to the panel for review.
Collaborator Contribution Reviews and discusses developments and makes suggestions for the future direction of research, outreach and industrial related engagement.
Impact Numerous outputs and actions, best summarised in the actions and summaries in the IAB minutes.
Start Year 2015
 
Description International Advisory Board, IAB 
Organisation University of Cambridge
Department Jesus College
Country United Kingdom 
Sector Academic/University 
PI Contribution Scientific presentation of the current research and developments to the panel for review.
Collaborator Contribution Reviews and discusses developments and makes suggestions for the future direction of research, outreach and industrial related engagement.
Impact Numerous outputs and actions, best summarised in the actions and summaries in the IAB minutes.
Start Year 2015
 
Description International Advisory Board, IAB 
Organisation University of Queensland
Department School of Population Health
Country Australia 
Sector Academic/University 
PI Contribution Scientific presentation of the current research and developments to the panel for review.
Collaborator Contribution Reviews and discusses developments and makes suggestions for the future direction of research, outreach and industrial related engagement.
Impact Numerous outputs and actions, best summarised in the actions and summaries in the IAB minutes.
Start Year 2015
 
Description International Advisory Board, IAB 
Organisation University of Wisconsin-Madison
Country United States 
Sector Academic/University 
PI Contribution Scientific presentation of the current research and developments to the panel for review.
Collaborator Contribution Reviews and discusses developments and makes suggestions for the future direction of research, outreach and industrial related engagement.
Impact Numerous outputs and actions, best summarised in the actions and summaries in the IAB minutes.
Start Year 2015
 
Description JLR - PhD Studentship Aluminium Alloy Development - Jiao Fang 
Organisation Jaguar Land Rover Automotive PLC
Department Jaguar Land Rover
Country United Kingdom 
Sector Private 
PI Contribution Aluminium Alloy Development. The research team has designed alloys, conducted casting and characterisation to obtain a fundamental understanding of Al-Ni-Mn alloy and its performance at room temperature and elevated temperatures.
Collaborator Contribution JLR provide the funding and organise regular project meetings to monitor progress.
Impact A good understanding of Al-Ni-Mn system and its performance at elevated temperatures have been obtained. The effects of minor element addition are also investigated and the fundamental knowledge obtained is communicated to the partners.
Start Year 2016
 
Description Lightweight Energy Absorbing Aluminium Structures (LEAAST) 
Organisation Constellium
Country France 
Sector Private 
PI Contribution BCAST has developed alloys and casting technologies that enable extrusions and castings to be combined in novel ways to produce a new generation of compact lightweight crash management systems. This includes a high strength alloy combined with casting alloys using overcasting techniques and the use of bonded and riveted joints to demonstrate the potential for both increased crash resistance and weight saving.
Collaborator Contribution Lightweight crash management systems are of increasing importance for most forms of ground transport. Automotive OEMs like JLR have advanced aluminium automotive body designs but still depend on steel for bumper beams. For rail applications steel based crash systems predominate. Constellium has developed considerably stronger extrusion alloys based on the AA6xxx alloy system that are fully recycling compatible with the sheet used for automotive structures and body panels.
Impact This project will demonstrated and evaluated optimised designs for crash management systems for both automotive and rail transport. Full scale prototypes of the new automotive CMS were manufactured in the Advanced Metal Casting Centre (AMCC)and were benchmarked against the incumbent versions and their simulations through a series of crash tests. The performance of the Oleo rail aluminium CMS prototype was compared with their current steel designs. For the first time, lighter CMS for rail applications were developed using both the high strength AA6xxx alloys and innovative fabrication routes.
Start Year 2015
 
Description Lightweight Energy Absorbing Aluminium Structures (LEAAST) 
Organisation Grainger & Worrall Limited
Country United Kingdom 
Sector Private 
PI Contribution BCAST has developed alloys and casting technologies that enable extrusions and castings to be combined in novel ways to produce a new generation of compact lightweight crash management systems. This includes a high strength alloy combined with casting alloys using overcasting techniques and the use of bonded and riveted joints to demonstrate the potential for both increased crash resistance and weight saving.
Collaborator Contribution Lightweight crash management systems are of increasing importance for most forms of ground transport. Automotive OEMs like JLR have advanced aluminium automotive body designs but still depend on steel for bumper beams. For rail applications steel based crash systems predominate. Constellium has developed considerably stronger extrusion alloys based on the AA6xxx alloy system that are fully recycling compatible with the sheet used for automotive structures and body panels.
Impact This project will demonstrated and evaluated optimised designs for crash management systems for both automotive and rail transport. Full scale prototypes of the new automotive CMS were manufactured in the Advanced Metal Casting Centre (AMCC)and were benchmarked against the incumbent versions and their simulations through a series of crash tests. The performance of the Oleo rail aluminium CMS prototype was compared with their current steel designs. For the first time, lighter CMS for rail applications were developed using both the high strength AA6xxx alloys and innovative fabrication routes.
Start Year 2015
 
Description Lightweight Energy Absorbing Aluminium Structures (LEAAST) 
Organisation Innoval Technology
Country United Kingdom 
Sector Private 
PI Contribution BCAST has developed alloys and casting technologies that enable extrusions and castings to be combined in novel ways to produce a new generation of compact lightweight crash management systems. This includes a high strength alloy combined with casting alloys using overcasting techniques and the use of bonded and riveted joints to demonstrate the potential for both increased crash resistance and weight saving.
Collaborator Contribution Lightweight crash management systems are of increasing importance for most forms of ground transport. Automotive OEMs like JLR have advanced aluminium automotive body designs but still depend on steel for bumper beams. For rail applications steel based crash systems predominate. Constellium has developed considerably stronger extrusion alloys based on the AA6xxx alloy system that are fully recycling compatible with the sheet used for automotive structures and body panels.
Impact This project will demonstrated and evaluated optimised designs for crash management systems for both automotive and rail transport. Full scale prototypes of the new automotive CMS were manufactured in the Advanced Metal Casting Centre (AMCC)and were benchmarked against the incumbent versions and their simulations through a series of crash tests. The performance of the Oleo rail aluminium CMS prototype was compared with their current steel designs. For the first time, lighter CMS for rail applications were developed using both the high strength AA6xxx alloys and innovative fabrication routes.
Start Year 2015
 
Description Lightweight Energy Absorbing Aluminium Structures (LEAAST) 
Organisation Jaguar Land Rover Automotive PLC
Department Jaguar Land Rover
Country United Kingdom 
Sector Private 
PI Contribution BCAST has developed alloys and casting technologies that enable extrusions and castings to be combined in novel ways to produce a new generation of compact lightweight crash management systems. This includes a high strength alloy combined with casting alloys using overcasting techniques and the use of bonded and riveted joints to demonstrate the potential for both increased crash resistance and weight saving.
Collaborator Contribution Lightweight crash management systems are of increasing importance for most forms of ground transport. Automotive OEMs like JLR have advanced aluminium automotive body designs but still depend on steel for bumper beams. For rail applications steel based crash systems predominate. Constellium has developed considerably stronger extrusion alloys based on the AA6xxx alloy system that are fully recycling compatible with the sheet used for automotive structures and body panels.
Impact This project will demonstrated and evaluated optimised designs for crash management systems for both automotive and rail transport. Full scale prototypes of the new automotive CMS were manufactured in the Advanced Metal Casting Centre (AMCC)and were benchmarked against the incumbent versions and their simulations through a series of crash tests. The performance of the Oleo rail aluminium CMS prototype was compared with their current steel designs. For the first time, lighter CMS for rail applications were developed using both the high strength AA6xxx alloys and innovative fabrication routes.
Start Year 2015
 
Description Lightweight Energy Absorbing Aluminium Structures (LEAAST) 
Organisation Luxfer Gas Cylinders
Country United Kingdom 
Sector Private 
PI Contribution BCAST has developed alloys and casting technologies that enable extrusions and castings to be combined in novel ways to produce a new generation of compact lightweight crash management systems. This includes a high strength alloy combined with casting alloys using overcasting techniques and the use of bonded and riveted joints to demonstrate the potential for both increased crash resistance and weight saving.
Collaborator Contribution Lightweight crash management systems are of increasing importance for most forms of ground transport. Automotive OEMs like JLR have advanced aluminium automotive body designs but still depend on steel for bumper beams. For rail applications steel based crash systems predominate. Constellium has developed considerably stronger extrusion alloys based on the AA6xxx alloy system that are fully recycling compatible with the sheet used for automotive structures and body panels.
Impact This project will demonstrated and evaluated optimised designs for crash management systems for both automotive and rail transport. Full scale prototypes of the new automotive CMS were manufactured in the Advanced Metal Casting Centre (AMCC)and were benchmarked against the incumbent versions and their simulations through a series of crash tests. The performance of the Oleo rail aluminium CMS prototype was compared with their current steel designs. For the first time, lighter CMS for rail applications were developed using both the high strength AA6xxx alloys and innovative fabrication routes.
Start Year 2015
 
Description Lightweight Energy Absorbing Aluminium Structures (LEAAST) 
Organisation Norton Aluminium Ltd
Country United Kingdom 
Sector Private 
PI Contribution BCAST has developed alloys and casting technologies that enable extrusions and castings to be combined in novel ways to produce a new generation of compact lightweight crash management systems. This includes a high strength alloy combined with casting alloys using overcasting techniques and the use of bonded and riveted joints to demonstrate the potential for both increased crash resistance and weight saving.
Collaborator Contribution Lightweight crash management systems are of increasing importance for most forms of ground transport. Automotive OEMs like JLR have advanced aluminium automotive body designs but still depend on steel for bumper beams. For rail applications steel based crash systems predominate. Constellium has developed considerably stronger extrusion alloys based on the AA6xxx alloy system that are fully recycling compatible with the sheet used for automotive structures and body panels.
Impact This project will demonstrated and evaluated optimised designs for crash management systems for both automotive and rail transport. Full scale prototypes of the new automotive CMS were manufactured in the Advanced Metal Casting Centre (AMCC)and were benchmarked against the incumbent versions and their simulations through a series of crash tests. The performance of the Oleo rail aluminium CMS prototype was compared with their current steel designs. For the first time, lighter CMS for rail applications were developed using both the high strength AA6xxx alloys and innovative fabrication routes.
Start Year 2015
 
Description Lightweight Energy Absorbing Aluminium Structures (LEAAST) 
Organisation Sarginsons Industries Ltd
Country United Kingdom 
Sector Private 
PI Contribution BCAST has developed alloys and casting technologies that enable extrusions and castings to be combined in novel ways to produce a new generation of compact lightweight crash management systems. This includes a high strength alloy combined with casting alloys using overcasting techniques and the use of bonded and riveted joints to demonstrate the potential for both increased crash resistance and weight saving.
Collaborator Contribution Lightweight crash management systems are of increasing importance for most forms of ground transport. Automotive OEMs like JLR have advanced aluminium automotive body designs but still depend on steel for bumper beams. For rail applications steel based crash systems predominate. Constellium has developed considerably stronger extrusion alloys based on the AA6xxx alloy system that are fully recycling compatible with the sheet used for automotive structures and body panels.
Impact This project will demonstrated and evaluated optimised designs for crash management systems for both automotive and rail transport. Full scale prototypes of the new automotive CMS were manufactured in the Advanced Metal Casting Centre (AMCC)and were benchmarked against the incumbent versions and their simulations through a series of crash tests. The performance of the Oleo rail aluminium CMS prototype was compared with their current steel designs. For the first time, lighter CMS for rail applications were developed using both the high strength AA6xxx alloys and innovative fabrication routes.
Start Year 2015
 
Description Lightweight Energy Absorbing Aluminium Structures (LEAAST) 
Organisation T. A. Savery & Co Limited
Country United Kingdom 
Sector Private 
PI Contribution BCAST has developed alloys and casting technologies that enable extrusions and castings to be combined in novel ways to produce a new generation of compact lightweight crash management systems. This includes a high strength alloy combined with casting alloys using overcasting techniques and the use of bonded and riveted joints to demonstrate the potential for both increased crash resistance and weight saving.
Collaborator Contribution Lightweight crash management systems are of increasing importance for most forms of ground transport. Automotive OEMs like JLR have advanced aluminium automotive body designs but still depend on steel for bumper beams. For rail applications steel based crash systems predominate. Constellium has developed considerably stronger extrusion alloys based on the AA6xxx alloy system that are fully recycling compatible with the sheet used for automotive structures and body panels.
Impact This project will demonstrated and evaluated optimised designs for crash management systems for both automotive and rail transport. Full scale prototypes of the new automotive CMS were manufactured in the Advanced Metal Casting Centre (AMCC)and were benchmarked against the incumbent versions and their simulations through a series of crash tests. The performance of the Oleo rail aluminium CMS prototype was compared with their current steel designs. For the first time, lighter CMS for rail applications were developed using both the high strength AA6xxx alloys and innovative fabrication routes.
Start Year 2015
 
Description Lightweight Energy Absorbing Aluminium Structures (LEAAST) 
Organisation University of Strathclyde
Department Advanced Forming Research Centre
Country United Kingdom 
Sector Academic/University 
PI Contribution BCAST has developed alloys and casting technologies that enable extrusions and castings to be combined in novel ways to produce a new generation of compact lightweight crash management systems. This includes a high strength alloy combined with casting alloys using overcasting techniques and the use of bonded and riveted joints to demonstrate the potential for both increased crash resistance and weight saving.
Collaborator Contribution Lightweight crash management systems are of increasing importance for most forms of ground transport. Automotive OEMs like JLR have advanced aluminium automotive body designs but still depend on steel for bumper beams. For rail applications steel based crash systems predominate. Constellium has developed considerably stronger extrusion alloys based on the AA6xxx alloy system that are fully recycling compatible with the sheet used for automotive structures and body panels.
Impact This project will demonstrated and evaluated optimised designs for crash management systems for both automotive and rail transport. Full scale prototypes of the new automotive CMS were manufactured in the Advanced Metal Casting Centre (AMCC)and were benchmarked against the incumbent versions and their simulations through a series of crash tests. The performance of the Oleo rail aluminium CMS prototype was compared with their current steel designs. For the first time, lighter CMS for rail applications were developed using both the high strength AA6xxx alloys and innovative fabrication routes.
Start Year 2015
 
Description Luxfer MEL Technologies - MC-DC casting trial 
Organisation Luxfer MEL Technologies
Country United Kingdom 
Sector Private 
PI Contribution This was a first industrial trial opportunity for MC-DC casting for Magnesium alloys. Currently, there is no existence of an efficient and consistent grain refiner for Mg alloys, especially for Aluminium containing Mg-alloys.
Collaborator Contribution The approach from MEL was to try the physical treatment by high shear melt conditioning in their existing twin-strand DC casting facility in order to investigate if finer grain structure is achievable compared to their normal production practice.
Impact The trial was a great success with a smooth demonstration of the MC-DC technology to produce billets of 12" diameter and 4.5metre length, with quite a significant reduction of grain size. The company is now in process of evaluating the cost and timing plan for integrating the HSMC technology into their recently planned refurbishment and upgrading of their existing DC-casting cells, which will lead to further integration of the HSMC technology into their ingot casting facility and thin gauge twin-roll casting facility overseas.
Start Year 2017
 
Description Melt conditioned direct chill (MC-DC) casting of large scale 7xxx series Al-alloy at Arconic 
Organisation Arconic
Country United States 
Sector Private 
PI Contribution Performed the trials of melt conditioned direct chill (MC-DC) casting of large scale 7xxx series Al-alloy at Arconic in the USA.
Collaborator Contribution The motivation behind these large-scale trials is to reduce the severe chemical segregation that takes place in these kinds of castings, where current Al-Ti-B based grainers are not able to control the chemical segregation as required to avoid large crack formation upon final solidification and facilitate the thermomechanical processing such as extrusion and forging.
Impact This trial is currently in the process of planning to first ship the HSMC equipment (Model: HSMC-Al-90) to a nominated Arconic facility to perform MC-DC casting of a 7xxx series Al-alloy on a 22" inch diameter 4-strand table, and secondly for the first time, perform MC-DC casting trial on a rectangular single strand table to cast a large slab of 24 inch thickness by 66 inch wide and 100 inch length.
Start Year 2019
 
Description NATEP - Studentship Guangyu Liu 
Organisation Chemring Energetic UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution We developed tin based alloys (Sn-Zn-Bi) in placement of currently-used lead alloys for the application of miniature detonating cords for aerospace applications.
Collaborator Contribution Regular meetings were held to steer the research to their industrial product requirements.
Impact 4 journal papers were drafted. 3 of them have or will soon be published and another is under review after minor revision. This is not a multi-disciplinary project. The partner has made the product (detonating cords) with the alloys developed by us, and have verified the final performance of them.
Start Year 2016
 
Description NUPRO project 
Organisation Ulster University
Country United Kingdom 
Sector Academic/University 
PI Contribution Award is £37,490.00 (£29,992.00 at 80% FEC)
Collaborator Contribution Award is £37,490.00 (£29,992.00 at 80% FEC) given by LiME Hub to Ulster University.
Impact The aim of this work is to establish that the NPF approach that has been developed for transparent analogue materials, can be applied to in-situ results for a metallic alloy studied by x-ray radiography. Objectives relate to a publication to include the following: • The development of a bespoke NPF model to account specifically for metal alloy solidification, including: o the thermal characteristic of the experimental furnace and o the thin sample geometry used in in-situ radiography • The application of the NPF model to a suite of experimental data in metallic alloys to be supplied by researchers Prof Mathiesen at NTNU and Prof. Browne at UCD. • The critical evaluation of the performance of the NPF approach to metallic alloys with particular focus on the suppression of nucleation due to dendritic growth (engulfment), latent heat (recalesence), and solute rejection to the liquid (solute poising).
Start Year 2020
 
Description Next Generation of Automotive Casting Alloys at AMCC 
Organisation Jaguar Land Rover Automotive PLC
Department Jaguar Land Rover
Country United Kingdom 
Sector Private 
PI Contribution Developed and worked on the theoretical understanding of aluminium alloys and alloy development for specific targets.
Collaborator Contribution Provide the industrial guidance and review throughout the project.
Impact Three alloys have been developed for the industrial partners and 4 patents issued to JLR.
Start Year 2016
 
Description Primetals Technologies 
Organisation Primetals technologies ltd
Country United Kingdom 
Sector Private 
PI Contribution Research and output aligned to the industrial product requirements; development of the melt conditioning feeding compartment for the Twin Roll casting; fixing and maintaining the Twin Roll Caster; optimisation of the operating conditions such as roll speed, set back, chilled water temperature, melt temperature and roll gap for each sheet gauge required; microstrucural analysis with thermomechanical treatment.
Collaborator Contribution Technical and financial support in addition to supplying all recycled AA5754 and AA6111 alloys as source material that was used to develop the melt conditioning twin roll casting process.
Impact Successfully two recycled alloys (AA5754 and AA6111) were cast in conventional TRC and melt conditioning MC-TRC with different gauge size of strip, with mechanical tests achieved for TRC and MC-TRC strips. Two papers published in JOM journal and work presented at two conferences.
Start Year 2015
 
Description Recycling of Aluminium through Innovative Technology (REALITY) 
Organisation Axion Recycling Ltd
Country United Kingdom 
Sector Private 
PI Contribution Full scale recycled scrap based sheet and castings will be produced and evaluated. The recovered wrought and cast scrap will be alloyed, melt conditioned to remove or tolerate impurities and then supplied for either coil production or for the commercial scale shape casting production by high pressure vacuum diecasting. Materials evaluation and characterisation will be carried out on both the resultant sheet and cast product forms.
Collaborator Contribution End-of-life vehicles will be shredded and automatically sorted using state of the art sensing and sorting technologies. The collaborators will supply the source material ingots from recycled Tiant Taber (TT), Bottom Ash (BA) and end of life car (ELV).
Impact The 36 month REALITY project will enable the development and industrial deployment of sensor-based scrap sorting technologies to separate wrought and cast alloys and then to further separate wrought alloys into alloy types for the first time. The Taint Tabor (TT) recycled material (supplied by Norton) and the Bottom Ash(BA) (supplied by Scanmetals) are successfully cast in Billets and extruded into thin planks without any casting defect by applying Melt conditioning in Direct Chill (DC) process.
Start Year 2017
 
Description Recycling of Aluminium through Innovative Technology (REALITY) 
Organisation Innoval Technology
Country United Kingdom 
Sector Private 
PI Contribution Full scale recycled scrap based sheet and castings will be produced and evaluated. The recovered wrought and cast scrap will be alloyed, melt conditioned to remove or tolerate impurities and then supplied for either coil production or for the commercial scale shape casting production by high pressure vacuum diecasting. Materials evaluation and characterisation will be carried out on both the resultant sheet and cast product forms.
Collaborator Contribution End-of-life vehicles will be shredded and automatically sorted using state of the art sensing and sorting technologies. The collaborators will supply the source material ingots from recycled Tiant Taber (TT), Bottom Ash (BA) and end of life car (ELV).
Impact The 36 month REALITY project will enable the development and industrial deployment of sensor-based scrap sorting technologies to separate wrought and cast alloys and then to further separate wrought alloys into alloy types for the first time. The Taint Tabor (TT) recycled material (supplied by Norton) and the Bottom Ash(BA) (supplied by Scanmetals) are successfully cast in Billets and extruded into thin planks without any casting defect by applying Melt conditioning in Direct Chill (DC) process.
Start Year 2017
 
Description Recycling of Aluminium through Innovative Technology (REALITY) 
Organisation Jaguar Land Rover Automotive PLC
Department Jaguar Land Rover
Country United Kingdom 
Sector Private 
PI Contribution Full scale recycled scrap based sheet and castings will be produced and evaluated. The recovered wrought and cast scrap will be alloyed, melt conditioned to remove or tolerate impurities and then supplied for either coil production or for the commercial scale shape casting production by high pressure vacuum diecasting. Materials evaluation and characterisation will be carried out on both the resultant sheet and cast product forms.
Collaborator Contribution End-of-life vehicles will be shredded and automatically sorted using state of the art sensing and sorting technologies. The collaborators will supply the source material ingots from recycled Tiant Taber (TT), Bottom Ash (BA) and end of life car (ELV).
Impact The 36 month REALITY project will enable the development and industrial deployment of sensor-based scrap sorting technologies to separate wrought and cast alloys and then to further separate wrought alloys into alloy types for the first time. The Taint Tabor (TT) recycled material (supplied by Norton) and the Bottom Ash(BA) (supplied by Scanmetals) are successfully cast in Billets and extruded into thin planks without any casting defect by applying Melt conditioning in Direct Chill (DC) process.
Start Year 2017
 
Description Recycling of Aluminium through Innovative Technology (REALITY) 
Organisation Norton Aluminium Ltd
Country United Kingdom 
Sector Private 
PI Contribution Full scale recycled scrap based sheet and castings will be produced and evaluated. The recovered wrought and cast scrap will be alloyed, melt conditioned to remove or tolerate impurities and then supplied for either coil production or for the commercial scale shape casting production by high pressure vacuum diecasting. Materials evaluation and characterisation will be carried out on both the resultant sheet and cast product forms.
Collaborator Contribution End-of-life vehicles will be shredded and automatically sorted using state of the art sensing and sorting technologies. The collaborators will supply the source material ingots from recycled Tiant Taber (TT), Bottom Ash (BA) and end of life car (ELV).
Impact The 36 month REALITY project will enable the development and industrial deployment of sensor-based scrap sorting technologies to separate wrought and cast alloys and then to further separate wrought alloys into alloy types for the first time. The Taint Tabor (TT) recycled material (supplied by Norton) and the Bottom Ash(BA) (supplied by Scanmetals) are successfully cast in Billets and extruded into thin planks without any casting defect by applying Melt conditioning in Direct Chill (DC) process.
Start Year 2017
 
Description Recycling of Aluminium through Innovative Technology (REALITY) 
Organisation Novelis
Country United States 
Sector Private 
PI Contribution Full scale recycled scrap based sheet and castings will be produced and evaluated. The recovered wrought and cast scrap will be alloyed, melt conditioned to remove or tolerate impurities and then supplied for either coil production or for the commercial scale shape casting production by high pressure vacuum diecasting. Materials evaluation and characterisation will be carried out on both the resultant sheet and cast product forms.
Collaborator Contribution End-of-life vehicles will be shredded and automatically sorted using state of the art sensing and sorting technologies. The collaborators will supply the source material ingots from recycled Tiant Taber (TT), Bottom Ash (BA) and end of life car (ELV).
Impact The 36 month REALITY project will enable the development and industrial deployment of sensor-based scrap sorting technologies to separate wrought and cast alloys and then to further separate wrought alloys into alloy types for the first time. The Taint Tabor (TT) recycled material (supplied by Norton) and the Bottom Ash(BA) (supplied by Scanmetals) are successfully cast in Billets and extruded into thin planks without any casting defect by applying Melt conditioning in Direct Chill (DC) process.
Start Year 2017
 
Description Recycling of Aluminium through Innovative Technology (REALITY) 
Organisation University of Warwick
Country United Kingdom 
Sector Academic/University 
PI Contribution Full scale recycled scrap based sheet and castings will be produced and evaluated. The recovered wrought and cast scrap will be alloyed, melt conditioned to remove or tolerate impurities and then supplied for either coil production or for the commercial scale shape casting production by high pressure vacuum diecasting. Materials evaluation and characterisation will be carried out on both the resultant sheet and cast product forms.
Collaborator Contribution End-of-life vehicles will be shredded and automatically sorted using state of the art sensing and sorting technologies. The collaborators will supply the source material ingots from recycled Tiant Taber (TT), Bottom Ash (BA) and end of life car (ELV).
Impact The 36 month REALITY project will enable the development and industrial deployment of sensor-based scrap sorting technologies to separate wrought and cast alloys and then to further separate wrought alloys into alloy types for the first time. The Taint Tabor (TT) recycled material (supplied by Norton) and the Bottom Ash(BA) (supplied by Scanmetals) are successfully cast in Billets and extruded into thin planks without any casting defect by applying Melt conditioning in Direct Chill (DC) process.
Start Year 2017
 
Description SAPA ProfiMelt Conditioning Direct Chill Casting of aluminium alloys 
Organisation SAPA Profiles UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution SAPA funded melt conditioning direct chill casting of aluminium alloys (6000 series). Trials were performed by our research team in the SAPA industrial facility in Belgium to produce melt conditioned billets of 206 mm diameter and 7 metre length. Working with SAPA, provided our first opportunity for trialling the newly developed MC-DC technology on an industrial scale. Our research provided SAPA with the opportunity to analyse the benefits of the MC-DC technology and how it could improve their products in their existing and future markets.
Collaborator Contribution Allowing trials to be performed on their product within their industrial plant. SAPA provided access to one of their production facilities to conduct a large scale industrial trial of the MC-DC technology.
Impact The objective was to produce billets with refined microstructure without using Ti and B based grain refiners and improve the intermetallic phase formation and distribution in a specifically developed 6000 series SAPA aluminium alloy, for easier downstream thermo-mechanical processing, and ultimately enhanced mechanical properties of finished products. After successful results from the first trial, the SAPA collaboration now focuses on MC-DC casting trials with deliberate increase of Fe/Mn content, in order to produce good quality billets with higher Fe tolerance. Successful realisation of the benefits of the MC-DC technology and its application to billet and extrusion profile production. This collaboration also led to the introduction of the large Chinese owned company CHINALCO.
Start Year 2015
 
Description Strain Enhanced Precipitates Aluminium - STEP AL 2018 
Organisation Constellium
Department Constellium UK Ltd
Country United Kingdom 
Sector Private 
PI Contribution Recently started EPSRC funded collaboration. Working to understand the solute-dislocation-precipitate interactions during thermomechanical processing of STEP Al alloys. This includes (1) how to enhance the nucleation process of precipitates during ageing with the assistance of both prior plastic deformation and trace element addition; and (2) how to achieve the highest possible stored dislocation density in the deformed Al-alloys with the assistance of precipitates.
Collaborator Contribution To develop novel component forming technologies to realise the full potential of STEP Al-alloys. This includes optimisation of the existing forming processes and further development of emerging forming processes To bridge the gap between fundamental research and engineering applications by addressing the full innovation value chain spanning the range of discovery, understanding, adaptation, integration, validation and deployment.To develop an integrated approach to component design through holistic integration of alloy chemistry, component manufacturing processes and component service conditions.
Impact Intended outcomes are: To develop a new generation of high performance Al-alloys for automotive applications, which have ultra-high strength, good ductility, high crashworthiness and high thermal conductivity; To further develop the novel melt-conditioned direct chill (MC-DC) casting process so that it can produce STEP alloy billets with refined grain size (without using grain refiner), fine uniformly dispersed second phase particles, uniform chemistry and significantly reduced casting defects.
Start Year 2018
 
Description TWI - PhD Studentship Andre Olivera 
Organisation TWI ltd
Country United Kingdom 
Sector Private 
PI Contribution An ongoing research project - joining dissimilar materials for future automotive structures - Developing new resistance welding technologies to create high integrity multi-material joints. Its aim is in relation to creating high integrity multi-material joints in a way suitable for a low cost high volume car production line.
Collaborator Contribution The industrial partner has provided a variety of joining technologies, materials to be joined and testing facilities. The industrial supervisor has also provided a wealth of knowledge in relation to the specifications of joints and invaluable information on industry needs.
Impact Currently preparing a manuscript.
Start Year 2016
 
Description TWI - PhD Studentship Andre Olivera 
Organisation University of Cambridge
Department Autism Research Centre (ARC)
Country United Kingdom 
Sector Academic/University 
PI Contribution An ongoing research project - joining dissimilar materials for future automotive structures - Developing new resistance welding technologies to create high integrity multi-material joints. Its aim is in relation to creating high integrity multi-material joints in a way suitable for a low cost high volume car production line.
Collaborator Contribution The industrial partner has provided a variety of joining technologies, materials to be joined and testing facilities. The industrial supervisor has also provided a wealth of knowledge in relation to the specifications of joints and invaluable information on industry needs.
Impact Currently preparing a manuscript.
Start Year 2016
 
Description TWI - PhD Studentship Harendra Kumar PhD 
Organisation TWI ltd
Country United Kingdom 
Sector Private 
PI Contribution This project, an integrated approach for evaluation of microstructure and mechanical properties degradation in steels used at elevated temperatures, is aimed at developing an integrated non-invasive approach for assessment of microstructure degradation and early detection of creep damage in creep strength enhanced ferritic steels and low alloy steel used at elevated operating temperature. A series of test samples having distinct microstructures with different levels of damage, by conducting accelerated heat-treatment with or without mechanical loading conditions, have been generated. As a part of this, EB welded cross weld specimen were machined and put on creep test for inducing defects. To induce the damage at desired location identification of a narrow range of test parameters has been established from techniques based on ultrasonic and electromagnetic methods, which correlate to a definite, discernible and consistent pattern with microstructural features.
Collaborator Contribution The industrial partner has provided large sections of welded steels, high temperature creep testing facilities, ultrasound inspection technology and other extensive lab support in accessing their facilities.
Impact Currently preparing a manuscript.
Start Year 2016
 
Description TWI - PhD Studentship Harendra Kumar PhD 
Organisation University of Cambridge
Department School of Clinical Medicine
Country United Kingdom 
Sector Academic/University 
PI Contribution This project, an integrated approach for evaluation of microstructure and mechanical properties degradation in steels used at elevated temperatures, is aimed at developing an integrated non-invasive approach for assessment of microstructure degradation and early detection of creep damage in creep strength enhanced ferritic steels and low alloy steel used at elevated operating temperature. A series of test samples having distinct microstructures with different levels of damage, by conducting accelerated heat-treatment with or without mechanical loading conditions, have been generated. As a part of this, EB welded cross weld specimen were machined and put on creep test for inducing defects. To induce the damage at desired location identification of a narrow range of test parameters has been established from techniques based on ultrasonic and electromagnetic methods, which correlate to a definite, discernible and consistent pattern with microstructural features.
Collaborator Contribution The industrial partner has provided large sections of welded steels, high temperature creep testing facilities, ultrasound inspection technology and other extensive lab support in accessing their facilities.
Impact Currently preparing a manuscript.
Start Year 2016
 
Description The Royal Society - Antibacterial Ti implants 
Organisation Institute of Metal Research, Chinese Academy of Sciences
Country China 
Sector Public 
PI Contribution We put forward a new concept of antibacterial performance for titanium implants with combined chemical and topographical modifications.
Collaborator Contribution Surface modifications will be carried out using titanium implants prepared by our Chinese partner.
Impact Materials preparation and characterisation are in progress as planned.
Start Year 2018
 
Description The Royal Society - Antibacterial Ti implants 
Organisation The Royal Society
Department The Royal Society Centre for History of Science
Country United Kingdom 
Sector Charity/Non Profit 
PI Contribution We put forward a new concept of antibacterial performance for titanium implants with combined chemical and topographical modifications.
Collaborator Contribution Surface modifications will be carried out using titanium implants prepared by our Chinese partner.
Impact Materials preparation and characterisation are in progress as planned.
Start Year 2018
 
Description The Wolfson Foundation 
Organisation The Wolfson Foundation
Country United Kingdom 
Sector Charity/Non Profit 
PI Contribution Contributions of the modelling team: The set-up and configuration of a computer cluster to support the Future LiME Hub's various activities in computational materials science and engineering, ranging from atomistic simulation of materials structures to modelling of materials processes. The modelling activities form a core feature of our fundamental and applied research in full metal circulation and manufacturing with light metals. Examples of computational work to support development of advanced processing technology includes a project on the simulation of high-pressure die casting (HPDC) and optimisation of the melt shearing process through computational fluid dynamics (CFD).
Collaborator Contribution Contribution of the Wolfson Foundation: £225,000 funding for the purchase of the computer cluster (800+ cores) and the refurbishment of the physical space in the Gardiner Building for the Virtual Engineering Centre.
Impact The Virtual Engineering Laboratory is a clustered computing facility funded by the Wolfson Foundation which has allowed high-quality computation of materials and processes at different length scales. The cluster enjoys UK's top networking infrastructure, maintained continually with minimal downtime, and is equipped with simulation software, including VASP, DL-Poly, and LAMMPS for atomistic simulation, FLUENT and OpenFOAM for computational fluid dynamics (CFD), ABAQUS for computational solid mechanics, ProCAST and FLOW-3D for casting simulation. The cluster is currently being used to its full capacity by several researchers who support the extensive research projects in materials and manufacturing.
Start Year 2016
 
Description Volkswagen - MC-TRC Mg Project 
Organisation Volkswagen
Country Germany 
Sector Private 
PI Contribution We are developing our melt conditioned (MC) twin roll casting concept, and verifying with Volkswagen for their magnesium thin sheet parts.
Collaborator Contribution They have provided their product requirements for our material and processing development.
Impact Na
Start Year 2018
 
Description ultraSonication for Tailoring Recycled Alloy Microstructures - STReAM 
Organisation Swansea University
Country United Kingdom 
Sector Academic/University 
PI Contribution Award is £37,209 (£29,767 at 80% FEC)
Collaborator Contribution Award is £37,209 (£29,767 at 80% FEC) given to Swansea University for the feasibility study of ultraSonication for Tailoring Recycled Alloy Microstructures - STReAM
Impact Overall aim of the research is to implement key intermetallic formation at the early stages of solidification under ultrasonication and then utilise such phases to grain refinement and microstructure modification in subsequent conventional solidification without ultrasonication.
Start Year 2020
 
Title A casting alloy 
Description This patent covers the development of a new casting alloy. 
IP Reference GB1616520.1 
Protection Patent application published
Year Protection Granted 2016
Licensed Yes
Impact This new alloy developed is now being transitioned into Jaguar Land Rover.
 
Title Al-nb-b master alloy for grain refining licensed to Norton Aluminium 
Description Initial patent (WO/2012/110788) for Al-nb-b master alloy for grain refining was licensed to Norton Aluminium in September 2016. 
IP Reference  
Protection Protection not required
Year Protection Granted 2016
Licensed Yes
Impact CBMM has been working directly with Norton. They produced several tonnes of master alloy and CBMM supplied this to several foundries.
 
Title Aluminium alloy for high pressure die casting 
Description Advancement of HPDC with new material development for JLR 
IP Reference GB1718332.8 
Protection Patent application published
Year Protection Granted 2017
Licensed Yes
Impact The present disclosure relates to an alloy and particularly, but not exclusively, to aluminium casting alloys for use in castings of structural components. Aspects of the invention relate to an alloy composition, and to a method of making and using such alloys. The aluminium alloy composition comprising: at least about 7.5 wt% and at most about 12.5 wt% silicon, at least about 2.0 wt% and at most about 5.5 wt% copper, at least about 0.3 wt%, and at most about 1.6 wt% magnesium.
 
Title Aluminium alloys for high pressure die casting 
Description Advancement of HPDC with new material development for JLR 
IP Reference GB1718791.5 
Protection Patent application published
Year Protection Granted 2017
Licensed Yes
Impact Impact to JLR, new material development. The present disclosure relates to an alloy and particularly, but not exclusively, to aluminium casting alloys for use in castings of structural components. Aspects of the invention relate to an alloy composition, the use of such an alloy composition, a cast product comprising an alloy composition, a vehicle comprising a cast product, and to a process for manufacturing a cast product. The aluminium alloy composition is provided, comprising: 3.0wt.% to 12.0wt.% magnesium; 0.5wt.% to 5.0 wt.% iron; optionally from 0.01wt.% to 1.5 wt.% rare earth element(s); optionally from 0.2wt.% to 2.5wt.% manganese; optionally from 5ppm to 100ppm beryllium; and other minor alloying elements and impurities, each in an amount of 0.4 wt.% or less, and less than 0.5 wt.% in total; with the balance being aluminium. Methods of making the composition are also provided, as well as cast products and methods of making cast products from the alloy composition.
 
Title HIGH STRENGTH CAST ALUMINIUM ALLOY FOR HIGH PRESSURE DIE CASTING 
Description A high strength cast aluminium alloy for high pressure die casting comprising magnesium silicide 6 to 12 wt. %, magnesium 4 to 10 wt. %, X element from copper (Cu), zinc (Zn), silver (Ag), gold (Au) and Lithium (Li) at 3 to 10 wt. %,manganese 0.1 to 1.2 wt. %, iron max. 1.5 wt. %, titanium or the other grain refining elements from Cr, Nb, and Sc with 0.02 to 0.4 wt. %, and impurity and minor alloying elements at a level of maximum 0.3 wt. % and totally <0.5% of at least one element selected from scandium (Sc), zirconium (Zr), Nickel (Ni), chromium (Cr), niobium (Nb), gadolinium (Gd), calcium (Ca), yttrium (Y), antinomy (Sb), bismuth (Bi), neodymium (Nd), ytterbium (Yb), vanadium (V), chromium (Cr), beryllium (Be) and boron (B) and the remainder aluminium. 
IP Reference US2016348220 
Protection Patent granted
Year Protection Granted 2016
Licensed Yes
Impact The development offers an opportunity for castings to replace forged parts used in aerospace and automotive industry.
 
Title High Modulus aluminium alloy 
Description Development of a new high modulus aluminium alloy 
IP Reference GB1800093.5 
Protection Patent application published
Year Protection Granted 2018
Licensed Yes
Impact Impact to JLR, new material development
 
Title High strength and ductility die cast aluminium alloy 
Description Development of a new high strength and ductile alloy for JLR 
IP Reference GB1713005.5 
Protection Patent application published
Year Protection Granted 2018
Licensed Yes
Impact Impact to JLR, new material development
 
Title METHODS AND PROCESS TO IMPROVE THE MECHANICAL PROPERTIES OF CAST ALUMINIUM ALLOYS AT AMBIENT TEMPERATURE AND AT ELEVATED TEMPERATURES 
Description Micro-alloyed aluminium alloys containing complex sub-micro /or nano- sized strengthening phases are provided for use in the automotive industry. The alloy is featured by adding at least one of the elements from Ni, Ag, Nb, Mo, Ce, La, Y and Sc at a level of more than 0.1wt.% but less than 0.5wt.% on top of the existing commercial alloy containing Si, Cu, Mg, Mn, Zn, and at least one type of sub-micron sized or even nano-sized TiB2, TiC and AI2O3 solid particles at a level of more than 0.05wt.% 
IP Reference EP3577243 
Protection Patent granted
Year Protection Granted 2019
Licensed No
Impact By increasing the mechanical properties of aluminium castings at room temperature and at elevated temperatures, the components can be designed in thin-wall and lightweight. This is one of the critical routes to achieve reduction of harmful emission gases.
 
Title Melt Conditioned Direct Chill (MC-DC) casting for Magnesium alloys 
Description Technology licensed: Melt Conditioned Direct Chill (MC-DC) casting for Magnesium alloys. To company: Luxfer MEL Technologies (LMT), Manchester, UK. Effective date from 1st December 2018. 
IP Reference  
Protection Protection not required
Year Protection Granted 2018
Licensed Yes
Impact Engagement and further research development and collaboration with company.
 
Title Methods and process to improve the mechanical properties of cast aluminium alloys at ambient temperature and at elevated temperatures 
Description Methods and process to improve the mechanical properties of cast aluminium alloys at ambient temperature and at elevated temperatures 
IP Reference GB1701667.6 
Protection Patent application published
Year Protection Granted 2017
Licensed No
Impact The next stage is to embed these novel processes within the automotive industry, of which there are direct links and alignment to their product requirements.
 
Title PURIFYING AN ALLOY MELT 
Description Device and method for melt treatment of aluminium alloys having excessive inclusions, impurities and unwanted gases to be removed, by (a) cooling the melt at an appropriate cooling rate to a temperature below the liquidus by shearing the melt associated with the introduction of at least one type of inert gases into the melt to form fine bubbles and high shear in the melt, and (b) purifying inclusions in the melt by floating them to the top surface, degassing the undesirable gases by reacting with the inert gas, and forming solid intermetallics containing impurity elements and transferring the melt mixture by the shearing device into a holding furnace, and (c) maintaining the melt in the holding furnace at a temperature below the liquidus and above the solidus temperature to settle the solid intermetallics formed by impurity elements as sediment at the bottom of the holding furnace while flowing the melt with much reduced inclusions, impurities and unwanted gases out of the holding furnace as applicable materials. The method is advantageously applicable for upgrading aluminium alloys from recycled and/or scrapped materials. 
IP Reference WO2016146980 
Protection Patent application published
Year Protection Granted 2016
Licensed No
Impact Castings of the automotive exhaust brackets have been made by the Fiat group.
 
Description "Sustainable Aluminium Automotive Alloys" ALFED-Automotive Industry Meet the Aluminium Industry Workshop 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact It is apparent that the automotive industry is in strong demand for aluminium and this demand is a chance for the sector to show how aluminium in automotive applications can and will be the sustainable future.
Year(s) Of Engagement Activity 2022
URL https://alfed.org.uk/eb-events/automotive-industry-meet-the-aluminium-industry/
 
Description A new die-cast magnesium alloy for applications at higher elevated temperatures of 200-300?°C 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at TMS 2020 conference, 149th Annual Meeting & Exhibition 23-27 Feb 2020 by X Dong & S Ji.
Title: A new die-cast magnesium alloy for applications at higher elevated temperatures of 200-300 °C
Year(s) Of Engagement Activity 2020
URL http://doi.org/10.1016/j.jma.2020.09.012
 
Description Advanced Forming Research Centre (AMRC) High Value Manufacturing Catapult 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Meetings to define future alignment of projects with AFRC Catapult and review supply chains and associated cross over to formulate future projects/collaborations.
Year(s) Of Engagement Activity 2016,2017,2018,2019
 
Description Advanced Metal Casting Centre launch articles - 2016 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Media engagement in relation to 'Shaping the Future', the opening of the Advanced Metal Casting Centre
https://www.brunel.ac.uk/news-and-events/news/articles/Shaping-the-Future-Casting-research-ramps-up-to-industrial-scale
https://www.foundrymag.com/meltpour/uk-metalcasting-rd-effort-secures-115m-funding
http://www.eurekamagazine.co.uk/design-engineering-news/brunel-opens-industrial-scale-casting-research-centre/117543/
http://www.machinery-market.co.uk/news/13806/Advanced-Metal-Casting-Centre-opens
Year(s) Of Engagement Activity 2016
URL https://www.brunel.ac.uk/news-and-events/news/articles/Shaping-the-Future-Casting-research-ramps-up-...
 
Description Advanced Metal Processing Centre launch articles - 2018 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Media engagements in relation to the opening of the Advanced Metal Processing Centre:
http://globenewswire.com/news-release/2018/06/13/1520793/0/en/Constellium-expands-R-D-capabilities-at-Brunel-University-London.html?f=22&fvtc=7
http://www.netfonds.se/quotes/release.php?id=20180613.GlobeNewswire.HUG2198945
http://www.4-traders.com/CONSTELLIUM-13267142/news/Constellium-expands-R-D-capabilities-at-Brunel-University-London-26759792/
http://www.stockwatch.com/News/Item.aspx?bid=U-z7302762-U:CSTM-20180613&symbol=CSTM®ion=U
http://www.sectorpublishingintelligence.co.uk/news/2012679/constellium+expands+rd+capabilities+at+brunel+university+london
https://www.finanzen.net/nachricht/aktien/constellium-expands-r-d-capabilities-at-brunel-university-london-6283979
https://www.nasdaq.com/press-release/constellium-expands-rd-capabilities-at-brunel-university-london-20180613-00116
http://www.netfonds.dk/quotes/release.php?id=20180613.GlobeNewswire.HUG2198945
http://www.finanzen.at/nachrichten/aktien/Constellium-expands-R&D-capabilities-at-Brunel-University-London-1026913801
http://www.lse.co.uk/regulatory-news-article.asp?ArticleCode=vfr2zjo9&ArticleHeadline=Constellium_expands_RD_capabilities_at_Brunel_University_London
https://www.ariva.de/news/constellium-expands-r-amp-d-capabilities-at-brunel-7025120
http://www.sectorpublishingintelligence.co.uk/news/2012679/constellium+expands+rd+capabilities+at+brunel+university+london
https://www.sharesmagazine.co.uk/news/market/6010248/Constellium-expands-RD-capabilities-at-Brunel-University-London
https://www.informazione.it/c/AA8D36C3-E58C-4296-A87A-F8BF7BB20A7B/Constellium-expands-RD-capabilities-at-Brunel-University-London
http://inpublic.globenewswire.com/2018/06/13/Constellium+expands+R+D+capabilities+at+Brunel+University+London+HUG2198945.html;jsessionid=Wc74LoLDbnNmVPdZDq5oRITY2gNRUJZ9aMJm1QhAv2dnxpBNMiLv!1439852794
http://www.investegate.co.uk/article.aspx?id=20180613090033H8945
http://www.moneyam.com/action/news/showArticle?id=6010248
https://www.benzinga.com/pressreleases/18/06/g11871265/constellium-expands-r-d-capabilities-at-brunel-university-london
https://forextv.com/top-news/constellium-expands-rd-capabilities-at-brunel-university-london/
http://research.tdameritrade.com/grid/public/markets/news/story.asp?fromPage=results&docKey=100-164g1848?ovider=HUG
https://www.finanznachrichten.de/nachrichten-2018-06/44037983-constellium-paris-constellium-expands-r-d-capabilities-at-brunel-university-london-399.htm
http://markets.businessinsider.com/news/stocks/constellium-expands-r-d-capabilities-at-brunel-university-london-1026913805
https://www.barchart.com/story/news/comtex/406458/constellium-expands-rd-capabilities-at-brunel-university-london
http://www.lessentiel.lu//fr/economie/nasdaq/?id=2198945&page=1&tab=0
http://www.euroinvestor.com/news/2018/06/13/constellium-expands-rd-capabilities-at-brunel-university-london/13842807
https://www.einpresswire.com/article/451349639/constellium-expands-r-d-capabilities-at-brunel-university-london
http://www.spoke.com/press_releases/5b20e95a2cf3f7f6cb0145c4
http://www.financialbuzz.com/constellium-expands-rd-capabilities-at-brunel-university-london-1116961
https://www.autobeatdaily.com/blog/post/constellium-expands-aluminum-tech-center-at-london-university
http://www.metalsnews.com/Metals+News/GlobeNewswire/GlobeNewswire+Newswire/MNNEWS1222806/Constellium+expands+RD+capabilities+at+Brunel+University+London.htm
https://www.autoblog.com/press-releases/constellium-expands-rd-capabilities-at-brunel-university-london_13083/
http://supplierinsight.ihsmarkit.com/news/5245539/constellium-expands-r-d-capabilities-in-uk-
https://www.just-auto.com/news/constellium-expands-brunel-university-aluminium-rd-centre_id183063.aspx
https://www.manufacturingchemist.com/news/article_page/Constellium_expands_RD_capabilities_at_Brunel_University/143987
http://automotivepurchasing.com/tier-suppliers/constellium-sets-up-rd-centre-at-brunel-university-london/
https://www.manufacturingchemist.com/news/article_page/Constellium_expands_RD_capabilities_at_Brunel_University/143987
https://steelguru.com/metal/constellium-expands-r-d-capabilities-at-brunel-university-london/512196
http://www.brunel.ac.uk/news-and-events/news/articles/New-metals-processing-centre-unveiled-at-Brunel
https://zenoot.com/new-metals-processing-centre-unveiled-at-brunel-university/
https://www.themanufacturer.com/articles/brunel-university-unveils-new-metal-processing-centre/
http://www.aluminiumtoday.com/news/view/new-metals-centre
https://zolmax.com/investing/constellium-cstm-earning-somewhat-favorable-media-coverage-report-finds/2325615.html
http://www.greencarcongress.com/2018/06/20180620-ampc.html
http://www.manufacturingmanagement.co.uk/news/brunel-unveils-new-metals-processing-centre
https://www.theengineer.co.uk/ampc-brunel/
https://worldindustrialreporter.com/ampc-introduces-new-metal-processing-and-casting-techniques/
http://www.mtimagazine.com/ampc-opens-at-bcast/
https://www.yerun.eu/2018/07/brunel-unveils-new-metals-processing-centre/
http://www.digitaljournal.com/pr/3869078
http://www.amm.com/Magazine/3823928/Features/Brunel-University-launches-additional-metal-R-D-center.html
http://www.amm.com/Magazine/3823929/Features/Constellium-expands-UTC-at-Brunel.html
http://www.indymedia.org.nz/articles/14997
http://prsync.com/market-research-future/automotive-structural-sheet-metal-market-global-analysis--forecast-to--research-report-2630516/
https://www.foundrymag.com/testingqc/expanded-auto-aluminum-rd-constellium
http://www.foundrytradejournal.com/news/advanced-solutions-for-an-advanced-project
https://zenoot.com/new-metals-processing-centre-unveiled-at-brunel-university/
http://www.greencarcongress.com/2018/06/20180620-ampc.html
http://www.aluminiumtoday.com/news/view/new-metals-centre
https://www.theengineer.co.uk/ampc-brunel/
https://www.themanufacturer.com/articles/brunel-university-unveils-new-metal-processing-centre/
https://worldindustrialreporter.com/ampc-introduces-new-metal-processing-and-casting-techniques/
http://www.mtimagazine.com/ampc-opens-at-bcast/
Year(s) Of Engagement Activity 2018
 
Description Advanced Propulsion Centre (APC) Lightweighting Roadmapping Workshops 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Defining the future roadmap for UK automotive vehicle lightweighting.
Year(s) Of Engagement Activity 2016,2017,2018
 
Description Aerospace Technology Institute (ATI) visit 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact The Aerospace Technology Institute (ATI) visited Brunel to discuss potential future projects aligned to the aerospace industry, to broaden our project breadth, currently more focused on the automotive sector.
Year(s) Of Engagement Activity 2018
 
Description Aluminium Alloy formulation from Shredded End-of-life Vehicles 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Online presentation given at the 4th Annual Vehicle Recycling Conference 25th November 2021
Event which offers a meeting place for top manufacturers, researchers, academics, decision-makers and other business professionals who are keen to share their knowledge and experience in the most pressing issues of vehicle dismantling. The conference represents a unique opportunity for learning, exchanging opinions, and expanding one's network enabled by live presentations followed by dynamic Q&A sessions - providing the attendees with valuable insights from the representatives of the biggest scrap metal recycling companies and leaders from automotive and manufacturing industries.
Year(s) Of Engagement Activity 2021
URL https://lp.bcf-events.com/4th-annual-vehicle-recycling-online-conference/#:~:text=ABOUT%20THE%20CONF...
 
Description Aluminium from Cans to Cars: Recycling the future 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Other audiences
Results and Impact Online presentation at the Warwick Manufacturing Group Research Colloquium on 27th April 2021
Year(s) Of Engagement Activity 2021
URL https://www.youtube.com/watch?v=wIosZiubzUY
 
Description Aluminium in Aerospace Conference 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Aluminium in Aerospace event held to understand the requirements of the Aerospace industry. Held with the support of the ATI & ALFED. 28 November 2019.
Year(s) Of Engagement Activity 2019
 
Description Aluminium recycling: Is there still magic? 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Blog posted on Innoval website
Year(s) Of Engagement Activity 2021
URL https://www.innovaltec.com/aluminium-recycling-still-magic-blog/
 
Description Apple 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Meetings with Apple to define their product requirements and processing requirements for a trial of the MC-DC, to remove their need for the use of a commercial grain refiner. With trials to be conducted at the Brunel AMCC facility.
Year(s) Of Engagement Activity 2016,2017,2018,2019
 
Description Arconic 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Meetings held with Arconic to enquire and learn more about the MC-DC casting technology and to especially review the status of the technology in terms of readiness for industrial application. As in the past few years, MC-DC casting of Aluminium has had a large scale casting opportunity, which meant that our in-house development of HSMC equipment was ready for industrial trials at one of Arconic's DC casting facilities. This engagement set up the basis for further collaborations via HSMC trials at the Arconic facility in the US. To date one MC-DC trial has been successfully achieved in their full scale 24 hour production facility. The project is now at the stage of evaluating the benefits of the MC-DC technology to a few selected Arconic products and in parallel technical discussions are in progress regarding integration design of the HSMC equipment to fit their casting procedures.
Year(s) Of Engagement Activity 2017,2018
 
Description Attandence at EBSD 2019 - Shohreh Khorsand 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Attendance at EBSD 2019
Year(s) Of Engagement Activity 2019
 
Description Attendance at MRE2020 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Attendance at Materials Research Exchange 2020
Year(s) Of Engagement Activity 2020
 
Description Beijing University of Aeronautics and Astronautics 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Meetings with Beijing University of Aeronautics and Stronautics to discuss research alignment.
Year(s) Of Engagement Activity 2017
 
Description Belarusian State University visit 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Visit from Belarusian State University to discuss future collaboration and alignment of fundamental research.
Year(s) Of Engagement Activity 2018
 
Description Brunel Catapult BEIS visits 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Policymakers/politicians
Results and Impact Brunel Catapult BEIS visits for assessment of our Catapult campaign and it's potential alignment with their HVM Catapult network.
Year(s) Of Engagement Activity 2016,2017,2018
 
Description Brunel University London Annual Research Conference 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Professional Practitioners
Results and Impact Exhibition stand and posters presented at Brunel's Annual Research Conference.
Year(s) Of Engagement Activity 2016,2017,2018
 
Description CAAHS project articles - 2018 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Media engagements in relation to the CAAHS project:
https://www.conceptcarz.com/a29152/carbon-aluminium-gordon-murray.aspx
https://www.theengineer.co.uk/c2i-2018-manufacturing-technology-sit-ski/
Year(s) Of Engagement Activity 2018
 
Description CASTcon 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact LiME attendance and posters at the UK cast metals industry conference: CASTcon - totally dedicated to the metal casting sector.
Year(s) Of Engagement Activity 2018
 
Description CSIRO (T-Mag Casting Technology) 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact T-Mag Casting Technology is a company in Australia associated with the CSIRO, Australia's national science agency. They are in the business of producing magnesium alloy castings for the automotive industry by their newly patented T-MAG process, which is an integrated casting technology for magnesium alloys that significantly extends the
capability and reduces the cost of permanent mould casting for a wide range of high-performance components. The LiME Hub integrated high shear melt conditioning technology within their 100kg magnesium alloy melting and casting furnace to evaluate the benefits of high shear on the quality of castings, which significantly improved.
Year(s) Of Engagement Activity 2015,2016
 
Description Cambridge University Institute for Manufacture (IFM) 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Other audiences
Results and Impact Visit to Cambridge IFM to build on LiME Hub BCAST roadmap.
Year(s) Of Engagement Activity 2018
 
Description Cast Metals Innovation award - BD1 alloy/Sarginsons - 2018 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Media engagements on the BD1 alloys with Sarginsons, including the Cast Metals Innovation award.
http://www.foundrytradejournal.com/features/impressive-project-from-start-to-finish
Year(s) Of Engagement Activity 2017,2018
URL http://www.foundrytradejournal.com/features/impressive-project-from-start-to-finish
 
Description Centre for Doctoral Training experience day 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact Our Centre for Doctoral Training experience day offers the opportunity for groups of 1st year PhD students from external CDT's to receive a more focussed insight into the research and processes utilised within the Future LiME Hub. Incorporating tours, demonstrations, presentations and practical work where appropriate, allowing students to gain a deeper understanding of the research, vision, and objectives and help us to ensure that we work with other institutions to encourage, facilitate, inform and build connections with the next generation of scientists and engineers.
Year(s) Of Engagement Activity 2016,2017,2018
 
Description Chair/Organiser of a symposium called "Aluminium Alloys" and co-editor of Light Metals 2020 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Dmitry Eskin: Chair/Organiser of a symposium called "Aluminium Alloys" and co-editor of Light Metals 2020
Year(s) Of Engagement Activity 2020
 
Description Chinalco 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Meetings to decide to perform a new record for MC-DC technology to date was made at Chinalco facility in China, where trials were conducted to evaluate the benefits of melt conditioning regards to producing large diameter billets for forging stock, where better microstructure and reduced chemical segregation were among the key achievements from this colossal trial.
Year(s) Of Engagement Activity 2015,2016
 
Description Chinese Academy of Science 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Meetings with Chinese Academy of Science to discuss potential future international research collaboration.
Year(s) Of Engagement Activity 2017,2018
 
Description Chongqing University 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Meeting with Chongqing University School of Materials Science and Engineering for potential research collaboration.
Year(s) Of Engagement Activity 2017,2018
 
Description Circular Economy Innovation Network Launch Event 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Other audiences
Results and Impact KTN have now set up an Circular Economy Innovation Network - Aluminium Group that held a virtual kick-off meeting on the 24th June 2022. Members of the team will also be involved in that group going forward.
Year(s) Of Engagement Activity 2022
URL https://iuk.ktn-uk.org/events/circular-economy-innovation-network-launch-event/
 
Description Coarsening-Resistance of a Severely Deformed Al-0.2 wt% Sc Alloy 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at TMS 2020 conference, 149th Annual Meeting & Exhibition 23-27 Feb 2020 by Y Huang.
Title: Coarsening-Resistance of a Severely Deformed Al-0.2 wt% Sc Alloy
Year(s) Of Engagement Activity 2020
URL http://doi.org/10.1007/978-3-030-36408-3_39
 
Description Cold Spray of Metallic Composites: From Dissimilar Bonding and Microstructure Evolution Towards Production of Gradient NiTi Intermetallics 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Cold Spray of Metallic Composites: From Dissimilar Bonding and Microstructure Evolution Towards Production of Gradient NiTi Intermetallics at ITSC 2021 on 15-18 June 2021 by R. Nikbakht, H. Assadi, B. Joboin
Year(s) Of Engagement Activity 2021
 
Description Constellium 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Meetings with Constellium to plan and and perform trials to study the potential benefits of melt conditioning on a 6082 alloy, one of the major regular production alloys of Constellium. The microstructure of a MC-DC billet was compared with the billet produced using commercial practice with Al-Ti-B grain refiner.
Year(s) Of Engagement Activity 2016,2017,2018,2019
 
Description Constellium Future Roadmapping Workshops 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Workshop lead by Brunel to create future roadmaps for the Constellium University Technology Centre (UTC) and R&D centre, and align with their associated production plants.
Year(s) Of Engagement Activity 2016,2017,2018
 
Description Constellium UTC and R&D Centre articles - 2016/2017/2018 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Articles in a number of sources in relation to the opening of the Constellium UTC and th R&D Centre.
For example:
https://www.metalbulletin.com/Article/3545551/base-metals/STEEL-VS-AL-Constelliums-tech-centre-will-push-automotive-aluminium-to-next-level.html
http://foundrymag.com/meltpour/lightweight-aluminum-research-center-opens-uk
http://www.ai-online.com/Adv/Previous/show_issue.php?id=7002
http://www.ai-online.com/Adv/Previous/show_issue.php?id=7567&search=true
https://www.eleconomista.com.mx/estados/Reino-Unido-y-NL-colaboraran-en-sector-automotriz-20181031-0002.html
3x official constellium press releases: https://www.constellium.com/news/2013/10/01/constellium-joins-forces-brunel-university-and-jaguar-land-rover-automotive-light
https://www.constellium.com/news/2016/04/07/constellium-inaugurates-its-new-state-art-university-technology-center-brunel
https://www.constellium.com/news/2018/06/13/constellium-expands-rd-capabilities-brunel-university-london
Year(s) Of Engagement Activity 2016,2017,2018
URL http://foundrymag.com/meltpour/lightweight-aluminum-research-center-opens-uk
 
Description Creativity@home 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Study participants or study members
Results and Impact Creativity@home workshop for everyone involved with the Future LiME Hub. We grouped everyone into their associated teams, and using Belbin team psychometric analysis we asked everyone to fill in an individual psychometric behavioral report before the workshop. Outputs from these reports were then fed into a team report, to identify their overall team dynamics and associated strengths and weaknesses. These were addressed with each team member within a day workshop, and how to enhance each team going forward for maximised efficiency and effectiveness. In the later part of the workshop, the teams were asked to look at the full metal circulation vision and determine how they think their research fits within, with a Future LiME Hub panel reviewing and guiding accordingly.
Year(s) Of Engagement Activity 2018
 
Description Dendritic Growth of Rapid-Solidified Eutectic High-Entropy Alloy 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Dendritic Growth of Rapid-Solidified Eutectic High-Entropy Alloy by L. Cao, P. Hou, A. Nassar, A. Mullis at Materials Science Forum 2021
Year(s) Of Engagement Activity 2021
URL http://doi.org/10.4028/www.scientific.net/msf.1035.46
 
Description Department for International Trade 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Supporters
Results and Impact Meetings with Department for International Trade to showcase our capabilities and future vision for pioneering the aluminium and magnesium industry, including impact to automotive OEMs and the entire supply chain.
Year(s) Of Engagement Activity 2016,2017
 
Description Development of a metal health service (MHS) for metallic components - The MHS project 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Public/other audiences
Results and Impact Development of a metal health service (MHS) for metallic components - The MHS project at NICER Programme ECR Summer School 14-16 March 2021 by E. Bagherpour.
Year(s) Of Engagement Activity 2021
 
Description Development of an Mg-RE-Based Die-Cast Magnesium Alloy for Elevated Applications 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Development of an Mg-RE-Based Die-Cast Magnesium Alloy for Elevated Applications at Magnesium 2021 on 15-18 June 2021 by X. Dong, L. Feng, E. Nyburg, S. Ji
Year(s) Of Engagement Activity 2021
URL http://doi.org/10.1007/978-3-030-72432-0_4
 
Description Development of lightweight materials for detonation cords in aircraft application 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Development of lightweight materials for detonation cords in aircraft application at LIMAS 2021 on 22-23 November 2021 by S. Ji
Year(s) Of Engagement Activity 2021
URL https://asranet.co.uk/Conferences/LIMAS
 
Description EBSD Analysis Enhancement of Cold Sprayed Composite Materials: Sample Preparation , Annealing, and Scan Optimization 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at Microscopical Society Symposium of Canada at Université de Sherbrooke, Québec, Canada, 2-5 June 2020 by H Assadi.
Title: EBSD Analysis Enhancement of Cold Sprayed Composite Materials: Sample Preparation , Annealing, and Scan Optimization
Year(s) Of Engagement Activity 2020
URL http://bura.brunel.ac.uk/handle/2438/21113
 
Description EPSRC Engineering Net Zero Week 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Other audiences
Results and Impact We exhibited a stand at the EPSRC Net Zero event in Glasgow, 20-24 June 2022
Year(s) Of Engagement Activity 2022
URL https://www.ukri.org/events/epsrc-engineering-net-zero-showcase/
 
Description EPSRC Hub Press Release - 2015 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact EPSRC press release "Johnson announces £20 million for Manufacturing Hubs"
Year(s) Of Engagement Activity 2015
URL https://epsrc.ukri.org/newsevents/news/manufacturinghubs/
 
Description Effect of Ultrasonic Melt Treatment on the Sump Profile and Microstructure of a Direct-chill Cast AA6008 Aluminum Alloy 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Effect of Ultrasonic Melt Treatment on the Sump Profile and Microstructure of a Direct-chill Cast AA6008 Aluminum Alloy by T. Subroto, B. Lebon, D. Eskin, I. Skalicky, D. Roberts, I. Tzanakis, K. Pericleous at Light Metals 2021 15-18 March 2021
Year(s) Of Engagement Activity 2021
URL http://doi.org/10.1007/978-3-030-65396-5_118
 
Description Effects of ultrasonic melt processing on microstructure, mechanical properties, and electrical conductivity of hypereutectic al-si, al-fe, and al-ni alloys with zr additions 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Effects of ultrasonic melt processing on microstructure, mechanical properties, and electrical conductivity of hypereutectic al-si, al-fe, and al-ni alloys with zr additions at Light Metals 2021 15-18 March 2021
Year(s) Of Engagement Activity 2021
URL http://doi.org/10.1007/978-3-030-65396-5_28
 
Description Electron Backscatter Diffraction Meeting 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Isaac Chang: Electron Backscatter Diffraction Meeting at National Physics Laboratory.
Year(s) Of Engagement Activity 2019
 
Description Engagement with students 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Postgraduate students
Results and Impact Co-I's working within Brunel University London's College of Engineering Design and Physical Sciences to provide lectures, seminars and engagement with undergraduates and postgraduate students.
Year(s) Of Engagement Activity 2015,2016,2017,2018,2019
 
Description Enhancing strength of light alloys through precipitation hardening 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Enhancing strength of light alloys through precipitation hardening at The 3rd ICYS & MANA Reunion Workshop by C. Mendis on 4-5 March 2021
Year(s) Of Engagement Activity 2021
URL https://www.nims.go.jp/mana/news_room/conference/2021011501.html
 
Description Exhibition presence - Advanced Engineering 2017 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Exhibition stand at Advanced Engineering, Birmingham
Year(s) Of Engagement Activity 2017
 
Description External launch of the Advanced Metal Processing Centre (AMPC) and the Constellium R&D centre 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Official launch of our new Advanced Metal Processing Centre (AMPC) facility and the Constellium R&D centre.
Year(s) Of Engagement Activity 2018
 
Description FLG flakes thickness and size control by varying the ultrasound parameters of eco-friendly LPE 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact FLG flakes thickness and size control by varying the ultrasound parameters of eco-friendly LPE at Graphene2021 26-29 October 2021 by A. Tyurnia, D. Eskin, I. Tzanakis, J Morton, K. Porfyrakis, N. Grobert
Year(s) Of Engagement Activity 2021
URL https://phantomsfoundation.com/GRAPHENECONF/2021/Abstracts/Grapheneconf2021_Tyurnina_Anastasia_64.pd...
 
Description Federal-Mogul Powertrain 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Meetings from interest generated from a published journal paper available online which focussed on MC-TRC of Al-alloys. Federal Mogul Powertrain is in the business of manufacturing lightweight bearings for automotive applications.These bearings are innovatively and precisely manufactured with mixed layers of polymer and metallic materials, giving them the characteristics of self-lubrication, zero maintenance and a longer service time. Al and Sn do not mix very well due to low solubility of Sn in molten Al, with Sn having a
melting point much lower than Al and a density much higher than Al. However, when Sn is added to Al-alloys, it gives the solid Al surface better sliding properties and an increased wear resistance. Hence, a fine and uniform distribution of the Sn-phase in the Al-matrix is highly necessary for better performance. They currently produce the Al-Sn alloy strips by the twin roll casting process, where they need to improve the distribution of the Sn phase in order to gain better performance. Within this trial the High Shear Melt Conditioned technology will be implemented and integrated into their existing launder system that feeds the twin roll caster. This will provide better preservation and solidification of the Sn-phase.
Year(s) Of Engagement Activity 2017,2018,2019
 
Description Formulation of Wrought Aluminium Alloys from Post-consumer Scrap Streams 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Online presentation at the IFAM: International Forum on Advanced Materials on 18th October 2021
Year(s) Of Engagement Activity 2021
 
Description Fractional Solidification for Purification of Recycled Aluminium Alloys 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at TMS 2020 conference, 149th Annual Meeting & Exhibition, 23-27 Feb 2020 by S Venditti & D Eskin.
Title: Fractional Solidification for Purification of Recycled Aluminium Alloys
Year(s) Of Engagement Activity 2020
URL http://doi.org/10.1007/978-3-030-36408-3_150
 
Description Generation of the Constellium R&D centre at Brunel 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Strategy meetings to formulate the Constellium R&D centre within Brunel and it's alignment with the Future LiME Hub.
Year(s) Of Engagement Activity 2017,2018
 
Description German Aerospace Centre, DLR 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact German Aerospace Centre, DLR visits and discussion for future work collaborations.
Year(s) Of Engagement Activity 2015,2016,2017,2018,2019
 
Description Good Lad Initiative 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Study participants or study members
Results and Impact Discussions and workshops attended in relation to promoting positive, equal and inclusive gender relationships (from the perspective of promoting positive masculinity) with the company Good Lad Initiative. Further conversations in relation to hosting more specific workshops are underway.
Year(s) Of Engagement Activity 2018
URL https://www.goodladinitiative.com/
 
Description Grain Refiner articles - 2016 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Media related engagements in relation to Hari Babu Nadendla's patented niobium grain refiner.
http://www.azom.com/news.aspx?newsID=45279
http://www.converternews.com/scientists-perfected-first-ever-grain-refiner-master-alloy-for-magnesium-aluminium-alloys/
https://www.aluminiumtoday.com/news/view/novel-research-on-cast-aluminium-products-wins-international-award
http://www.brunel.ac.uk/news-and-events/news/news-items/ne_466512
Year(s) Of Engagement Activity 2016
 
Description Grain refiner breakthrough honoured article 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Article hosted on Brunel's website 'Grain refiner breakthrough honoured', detailing the niobium master alloy, winner of the Charles Hatchett Prize and Medal and CMF's Innovation Award
Year(s) Of Engagement Activity 2016
URL http://www.brunel.ac.uk/news-and-events/news/news-items/ne_466512
 
Description Grainger and Worrall 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Meetings with Grainger & Worrall to plan and conduct a sand casting trial in September & December 2016, to evaluate the effect of melt conditioning on microstructure refinement and defect control for cast aluminium alloys such as A357 and A201, which are used in sand casting of automotive components including engine blocks and cylinder heads.
Year(s) Of Engagement Activity 2015,2016,2017
 
Description HPDC call out project with CMF 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Working with the Cast Metals Federation to develop further collaborations with SME's in relation to High Pressure Die Casting projects
Year(s) Of Engagement Activity 2019
 
Description Heathrow UTC visit 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Undergraduate students
Results and Impact 15-20 pupils attended a visit to BCAST (and another department within Brunel - MACE) and conducted experiments (non-destructive and destructive approach) with aluminium alloy and polyethylene specimens to gain a general understanding of metals and plastics response under load.
Year(s) Of Engagement Activity 2016,2017,2018
 
Description High Cycle Fatigue Properties of the Zr-modified Al-Si-Cu-Mg Alloy at Elevated Temperatures 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at TMS 2020 conference, 149th Annual Meeting & Exhibition 23-27 Feb 2020 by S Ji.
Title: High Cycle Fatigue Properties of the Zr-modified Al-Si-Cu-Mg Alloy at Elevated Temperatures
Year(s) Of Engagement Activity 2020
URL http://doi.org/10.1007/978-3-030-36408-3_36
 
Description High Strain-Rate Deformation Evolution of Ni and Ti in Cold Sprayed Composite Ni-Ti Coatings 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at IMAT 2020, Oct 26-28 2020 by H Assadi
Title: High Strain-Rate Deformation Evolution of Ni and Ti in Cold Sprayed Composite Ni-Ti Coatings
Year(s) Of Engagement Activity 2020
URL https://asm.confex.com/asm/imat2020/webprogram/Paper49807.html
 
Description High Value Manufacturing Catapult Visit to Brunel 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact High Value Manufacturing Catapult Chief Technology Officer (CTO) visit to BCAST/LiME to discuss alignment with their network, including strategic drivers and technology themes. This lead to us providing a Constellium case study to HVM Catapult, at their request, to use to try and better align fundamental research with their scale up research. This work is ongoing, and is building on our case to enter the HVM Catapult network with our AMCC and AMPC scale up facilities.
Year(s) Of Engagement Activity 2016,2017,2018,2019
 
Description Hosts of TMS course 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Hosts of the TMS 2017 Aluminium Cast Shop Science and Technology course, in conjunction with the IOM3.
Year(s) Of Engagement Activity 2017
 
Description Husqvarna Group (Sweden) 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Meetings with Husqvarna Group (Sweden) to formulate the Advanced Magnesium Piston Development project.
Year(s) Of Engagement Activity 2017,2018,2019
 
Description Husqvarna articles - 2018 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Media engagements in relation to the Husqvarna project:
http://www.brunel.ac.uk/news-and-events/news/articles/Lightweight-products-are-the-goal-for-new-magnesium-piston
http://www.industrinyheter.se/20180306/26249/husqvarna-utvecklar-magnesiumkolv-lattviktsprodukter
Year(s) Of Engagement Activity 2018
 
Description ICASP5 Attendance - Dmitry Eskin 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Conference attendance at ICASP5 by Dmitry Eskin 17-21 June 2019 in Salzburg, Austria.
Year(s) Of Engagement Activity 2019
 
Description Impol (Slovenia) 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Visit to Impol in Slovenia to discuss our research alignment to their casting and rolling processing. Further, they wanted advice of how to set up a scale up facility with their associated universities in collaboration.
Year(s) Of Engagement Activity 2018
 
Description Impression technologies 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Meetings to formulate APC7 Raceform project including Brunel and Impression Technologies.
Year(s) Of Engagement Activity 2017
 
Description Improving Ultrasonic Melt Treatment Efficiency Through Flow Management: Acoustic Pressure Measurements and Numerical Simulations 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at TMS 2020 conference, 149th Annual Meeting & Exhibition 23-27 Feb 2020 by T Subroto & D Eskin. Title: Improving Ultrasonic Melt Treatment Efficiency Through Flow Management: Acoustic Pressure Measurements and Numerical Simulations.
Year(s) Of Engagement Activity 2020
URL http://doi.org/10.1007/978-3-030-36408-3_132
 
Description Industrial Capability Leaflet 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Following on from the Industrial Communications strategy that came out of the ISP meeting, an Industrial Capability Highlights leaflet was produced, specifically designed to address wider dissemination of our research and capabilities to industry.
Year(s) Of Engagement Activity 2019
 
Description Industrial Steering Panel 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact The Industrial Steering Panel (ISP) represents the key strategic interests of the current and potential end-users of the research carried out within the Future LiME Hub. The members of the panel represent a wide array of contributors from casting and metallic processing industries to the manufacturers and users of the end products. They advise on the potential future opportunities for LiME's research to be applied to industrial and manufacturing needs and help to ensure the industrial relevance of our applied research.

The main objective of the ISP is to provide independent advice from an industrial perspective on the progress of the LiME projects and the overall strategic direction and relevance of the Hub's research. ISP membership is reviewed by the Hub Management Group annually to reflect the dynamic nature of the research programme.
Year(s) Of Engagement Activity 2016,2017,2018,2019
 
Description Innoval Framework Development 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Meeting to define and clarify the development of a framework for collaboration with LiME/BCAST.
Year(s) Of Engagement Activity 2018
 
Description Innoval Technology Blog 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact As part of Innovals Blog posts an article titled 'Recycled aluminium and the Aluminium Age' was posted.
Year(s) Of Engagement Activity 2017
URL https://www.innovaltec.com/recycled-aluminium-blog/
 
Description Institute of Physics visit 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Professional Practitioners
Results and Impact The Institute of Physics visited to gain an understanding of the fundamental research and facilities available and the wider impact.
Year(s) Of Engagement Activity 2018
 
Description Internal launch of the Advanced Metal Casting Centre (AMCC) and Advanced Metal Processing Centre (AMPC). 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Other audiences
Results and Impact Internal launch of BCAST Advanced Metal Casting Centre (AMCC) and Advanced Metal Processing Centre (AMPC).
Year(s) Of Engagement Activity 2018
 
Description International Advisory Board 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact The International Advisory Board (IAB) stand as experts in the areas of the Future LiME Hub's research. They advise the LiME Hub Management Group on strategic research directions and opportunities in solidification and casting research, benchmark the quality and progress of our research against the international stage and participate in the Hub's international activities. The members come from a number of renowned institutions from across the globe and have many years of experience within the field.

The IAB meets with the LiME Hub Management Group and researchers annually to receive and review updates on LiME's research and operational progress. The board have the opportunity to discuss developments and make suggestions for the future direction of research and industrial related engagement.
Year(s) Of Engagement Activity 2016,2017,2018
 
Description International Conference Host - Mg2018 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact International host of The 11th International Conference on Magnesium Alloys and Their Application - Mg2018. Bringing together academia and industry for knowledge exchange and leading scientific presentations on solidification science. A week long conference 24-27th July 2018, attended by over 222 delegates.
Year(s) Of Engagement Activity 2018
 
Description International Conference Host - SP17 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact International host of the The 6th Decennial Conference on Solidification Processing - SP17. Bringing together academia and industry for knowledge exchange and leading scientific presentations on solidification science. A week long conference 25-28th July 2018, attended by over 275 delegates. The event also featured a Round-table discussion on the directions of solidification research internationally.
Year(s) Of Engagement Activity 2017
 
Description International Magnesium Association 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact International Magnesium Association visits.
Year(s) Of Engagement Activity 2017,2018,2019
 
Description International Workshop, India 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Undergraduate students
Results and Impact 16 hours spent in workshops and presentations at the National Institute of Technology (NIT), India
Year(s) Of Engagement Activity 2018
 
Description Introduction to Fundamentals of Material Modelling & Simulation 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact Hamid Assadi - Speaker on Introduction to Fundamentals of Material Modelling & Simulation workshop. 13 July 2020
Year(s) Of Engagement Activity 2020
 
Description Invited Lecture on Mechanical Joining Processes in Automobile Industry (RACEFORM project) 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact Invited Lecture on Mechanical Joining Processes in Automobile Industry (RACEFORM project) at Shiraz University, Iran on 11 March 2019
Year(s) Of Engagement Activity 2019
 
Description Invited lecture at 3rd Conference & Exhibition on Light Materials (LightMAT 2019) 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Invited Lecture at 3rd Conference & Exhibition on Light Materials (LightMAT 2019). Deformation of a high purity magnesium single crystal in the c-axis (0001) direction. 5 - 7 November 2019 by Yan Huang in Manchester UK.
Year(s) Of Engagement Activity 2019
 
Description Is Aluminium a Fuel for Tomorrow? 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Blog posted on Innoval website
Year(s) Of Engagement Activity 2021
URL https://www.innovaltec.com/aluminium-fuel-for-tomorrow-blog/
 
Description JLR articles - REALITY project 2017 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Media engagements in relation to JLR and REALITY:
http://www.automotivebusiness.com.br/noticia/26374/jaguar-land-rover-aumentara-uso-de-aluminio-reciclado
http://www.truckbrasil.com.br/wp/2017/09/05/veiculos-jaguar-land-rover-terao-processo-mais-moderno-de-aluminio-reciclado/
http://blog.tribunadonorte.com.br/autosemotores/2017/09/06/veiculos-jaguar-land-rover-terao-processo-processo-mais-moderno-de-aluminio-reciclado/
https://www.theengineer.co.uk/jlr-new-life-old-aluminium/
https://livenews.co.nz/2017/09/07/new-zealand-motor-vehicle-sector-cars-reborn-in-a-new-aluminium-recycling-scheme/
https://lulop.com/it_IT/post/show/133665/il-programma-di-recupero-reali.html
https://www.repubblica.it/motori/sezioni/attualita/2017/09/07/news/jaguar_land_rover_aumenta_l_utilizzo_dell_alluminio_riciclato-174838117/
https://www.adnkronos.com/sostenibilita/in-pubblico/2017/09/07/jaguar-land-rover-potenzia-programma-riciclo-alluminio-vetture-rottamate_hPAZIXAy4cJk1PUF7dU8IM.html
www.eurekamagazine.co.uk/design-engineering-news/jlr-makes-closed-loop-aluminium-recycling-in-its-cars-a-reality/160509/
https://worldindustrialreporter.com/jaguar-land-rovers-reality-offers-second-innings-for-old-aluminium/
http://www.automanianet.com.br/2017/09/veiculos-da-jaguar-land-rover-terao-novo-processo-de-aluminio-reciclado/
http://www.revistafatorbrasil.com.br/ver_noticia.php?not=348199
https://www.aluminiumtoday.com/news/view/jlr-alu-recyling
https://www.greencarcongress.com/2017/09/20170911-jlr.html
https://motori.tiscali.it/socialmediamotori/articoli/jaguar-land-rover-ricicla-alluminio-rottamato-utilizzare-produzione-nuovi-veicoli-00001/
https://cleantechnica.com/2017/09/12/jaguar-land-rover-expanding-use-recycled-aluminum-car-bodies/
https://resource.co/article/new-project-sees-recycled-aluminium-used-jaguar-land-rovers-12107
http://mecanicaonline.com.br/wordpress/2017/09/29/veiculos-jaguar-land-rover-terao-processo-mais-moderno-de-aluminio-reciclado/
https://sustainablebrands.com/read/chemistry-materials-packaging/trending-vw-jlr-make-big-commitments-to-evs-circular-tech
http://www.4-traders.com/news/SMMT-Society-of-Motor-Manufacturers-and-Traders-Cars-reborn-in-new-aluminium-recycling-scheme--25585456/?utm_medium=RSS&utm_content=20171129
https://www.mrw.co.uk/latest/research-to-increase-recycling-of-aluminium-from-elvs/10027369.article
https://automotivemanufacturingsolutions.com/process-materials/aluminium-allegiance
https://www.greencarcongress.com/2017/05/20170512-brunel.html
https://insights.globalspec.com/article/5090/lighter-parts-for-more-sustainable-jaguar-land-rover-vehicles
https://www.aluminiumtoday.com/news/view/ultra-light-car-parts
https://www.metalbulletin.com/Article/3717668/base-metals/STEEL-VS-AL-Brunel-JLR-combine-on-lightweight-car-parts.html
http://www.brunel.ac.uk/news-and-events/news/articles/Brunel-research-helps-lighten-the-load-for-Jaguar-Land-Rover
Year(s) Of Engagement Activity 2017
 
Description Jaguar Land Rover Light Alloys Research Workshop 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Jaguar Land Rover Light Alloys Research Workshop to define roadmap of future projects and their alignment with LiME.
Year(s) Of Engagement Activity 2017,2018
 
Description Jo Johnson Opening speech for the launch of the Advanced Metal Casting Centre, YouTube 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact Youtube video hosted by Brunel University London featuring MP Jo Johnson's support of the AMCC.
Year(s) Of Engagement Activity 2016
URL https://www.youtube.com/watch?v=HS8ip4OZRp0
 
Description John Hunt Memorial Lecture 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Hosts of the annual IOM3 John Hunt award and memorial lecture.
Presented by Prof Wilfried Kurz, Prof Alain Karma and Prof Lindsay Greer.
Year(s) Of Engagement Activity 2016,2017,2018
 
Description LEAAST project articles - 2017 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Media engagements in relation to the collaboration with Sarginsons and the LEAAST project:
https://www.machinery-market.co.uk/news/18833/Aluminium-developments-are-driving-growth-
http://www.thebusinessdesk.com/westmidlands/news/2009296-automotive-demand-drives-growth-castings-firm
https://www.themanufacturer.com/articles/aluminium-growth-drives-uk-casting-firms-success/
https://www.insidermedia.com/insider/midlands/sarginsons-hails-successful-start-to-2017
http://www.machinery.co.uk/machinery-news/major-growth-witnessed-by-sarginsons-industries
http://www.brunel.ac.uk/news-and-events/news/articles/Bumper-boost-for-crash-protection-in-lightweight-vehicles
http://www.thebusinessdesk.com/westmidlands/news/2003278-coventry-manufacturer-pioneers-new-super-strength-lightweight-alloy-technology#.WR644fj8kRU.twitter
http://www.greencarcongress.com/2017/05/20170522-bcast.html
Year(s) Of Engagement Activity 2017
URL https://www.themanufacturer.com/articles/aluminium-growth-drives-uk-casting-firms-success/
 
Description Launch of the Advanced Metal Casting Centre (AMCC) 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Official launch of the Advanced Metal Casting Centre (AMCC) at Brunel University London and the Constellium R&D Centre. The day included presentations and tours of the facility.
Year(s) Of Engagement Activity 2015,2016
 
Description LiME PhD Training Course 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Postgraduate students
Results and Impact Held annually over a four week period, specialist training courses are held for PhD's on topics such as the Fundamentals of Metallurgy, Fundamentals of Metal Processing, Fundamentals of Materials and Process Modelling, Fundamentals of Materials Characterisation
Year(s) Of Engagement Activity 2017,2018
 
Description LiME Website 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact The Future LiME Hub's website was re-designed to reflect the new programme and its objectives.
Year(s) Of Engagement Activity 2014,2016
URL http://lime.ac.uk
 
Description London metal exchange 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Other audiences
Results and Impact Meeting with London metal exchange for analysis and review of the light metals industry.
Year(s) Of Engagement Activity 2018
 
Description Low Carbon Alloy Formulation from Secondary Aluminium 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Online presentation given at the ALUS 10: 10th International Aluminium Symposium, Istanbul, 3rd March 2022
10th International Aluminium Symposium was jointly organized by Turkish Aluminium Industrialists Association (TALSAD), TUBITAK Marmara Research Center and METEM-UCTEA Chamber of Metallurgical and Materials Engineers's Training Center and was held on March 3-4, 2022 at Istanbul Fair Center, Yesilköy, Istanbul. The symposium took place at the same place and time with the ALUEXPO 2021 7th International Aluminium Technologies, Machinery and Products Trade Fair organized by Hannover-Messe Ankiros Fair. 10th International Aluminum Symposium aimed to bring together aluminum sector and the academia on the same platform to share scientific and technological developments that will shape the industry in an international environment in all its dimensions. The main objective of this symposium was to inform participants about the recent developments and provide a vision for the future of Turkey's aluminium sector.
Year(s) Of Engagement Activity 2022
URL http://www.alusist.com/English/Report
 
Description Lunchtime Lecture Series 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact The lunchtime lecture series provides the opportunity for BCAST researchers and externally invited speakers to come in and present their current research to their peers.
External speakers have included: Professor Anders Jarfors (Jonkopping Univ); Dr. Javier Llorca (Madrid Inst. Adv. Studies of Materials); Dr Amir Shirzadi (Open University); Dr. James Campbell (BUL-National Structural Integrity Research Centre); Dr. Ali Mousavi (Department of Electronic and Computer Engineering Brunel University); Peter Hobson (Department of Electronic and Computer Engineering, Brunel University); Dr. Zhang Wenzheng (Tsinghua University - Beijing); Prof. Guangyin Yuan (Shanghai Jiao Tong University); Prof Sergei Molokov (Coventry University); Prof Guangyin Yuan (Shanghai Jiao Tong); Prof Baicheng Liu (Tsinghua University, China); Prof Wenzheng Zhang (Tsinghua University, China); Prof Mark Easton (RMIT, Australia); Louise Wright (National Physical Laboratory); Martin de Heaver (ORBIT)
Year(s) Of Engagement Activity 2015,2016,2017,2018
 
Description Luxfer MEL Technologies 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Engagements to discuss, plan and perform trials of our melt conditioned direct chill (MC-DC) casting for their AZ80 Mg-alloy at Magnesium Elektron (MEL), Manchester, UK. This has led to licensing opportunities in relation to the MC-DC technology.
Year(s) Of Engagement Activity 2017,2018,2019
 
Description MRS 2019 conference Boston USA - Invited speaker 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Enzo Liotti invited speaker to MRS 2019 in Boston USA.
Year(s) Of Engagement Activity 2019
 
Description Magna Cosma International 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Meetings with Magna Cosma International to formulate the Advanced Propulsion Centre 6 - CHAMELEON project.
Year(s) Of Engagement Activity 2017
 
Description Materials Research Exchange - MRE2018 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Exhibition stand at Materials Research Exchange, Angel Islington, London, March 2018. Exhibition and conference to showcase the UK materials research and investment opportunities providing information on current trends and future innovations, attended to promote LiME's research contribution to the UK Manufacturing landscape, gain knowledge and to further develop networks.
Year(s) Of Engagement Activity 2018
 
Description Meetings with Peers 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Other audiences
Results and Impact Lord David Brookman, a British steel worker and trade unionist, to showcase our research and facilities.
Lord Swraj Paul of Marylebone, showcasing of our research and facilities.
Lord Tim Boswell of Aynho, showcasing of our research and facilities.
Baroness Trixie Gardner of Parkes, showcasing of our research and facilities.
Year(s) Of Engagement Activity 2018
 
Description Mg-Alloys Are Self-Grain Refining 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at ICM2020 19-22 Nov 2020 by Z Fan.
Title: Mg-Alloys Are Self-Grain Refining
Year(s) Of Engagement Activity 2020
 
Description Microstructure Evolution of an Al-Fe-Ni Alloy with Zr and Sc Additions Upon Different Cooling Rates During Solidification for Improving the Mechanical and Electrical Conductivity Properties 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Microstructure Evolution of an Al-Fe-Ni Alloy with Zr and Sc Additions Upon Different Cooling Rates During Solidification for Improving the Mechanical and Electrical Conductivity Properties presentation at Light Metals 2021 by S. Chankitmunkong, D. Eskin, C. Limmaneevichitr
Year(s) Of Engagement Activity 2021
URL http://doi.org/10.1007/978-3-030-65396-5_34
 
Description Modelling of the High Pressure Die Casting Process 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at Shanghai Forum on Materials Frontier 2020 Spring (online) 28 April 2020 by K Dou.
Title: Modelling of the High Pressure Die Casting Process
Year(s) Of Engagement Activity 2020
 
Description Molecular Dynamics Simulations of Titanium Dioxide as Model System for Size Effects in Aerosol Deposition 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Molecular Dynamics Simulations of Titanium Dioxide as Model System for Size Effects in Aerosol Deposition at Thermal Spray 2021 24-28 May 2021 by B. Daneshian, F. Gaertner, W. Weber, T. Klassen, H. Assadi, D. Hoeche
Year(s) Of Engagement Activity 2021
URL http://doi.org/10.31399/asm.cp.itsc2021p0354
 
Description Mr. Adrian Bailey, MP (West Bromwich West) 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Policymakers/politicians
Results and Impact Meeting with Mr. Adrian Bailey, MP (West Bromwich West) to showcase our research and facilities and potential alignment with the casting industry, including Birmingham.
Year(s) Of Engagement Activity 2018
 
Description Mr. Boris Johnson, MP (Uxbridge) 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Policymakers/politicians
Results and Impact Mr. Boris Johnson, MP (Uxbridge - local area) visit to Brunel and shown around our state of the art facilities.
Year(s) Of Engagement Activity 2018
 
Description Mr. Steve McCabe, MP (Selly Oak, Birmingham) 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Policymakers/politicians
Results and Impact Meeting with Mr. Steve McCabe, MP (Selly Oak, Birmingham) to discuss our research and it's potential impact on the casting industry, including Birmingham.
Year(s) Of Engagement Activity 2017
 
Description Nanoindentation and Cavitation-Induced Fragmentation Study of Primary Al3Zr Intermetallics Formed in Al Alloys 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at TMS 2020 conference, 149th Annual Meeting & Exhibition, 23-27 Feb 2020 by T Subroto & D Eskin. Title: Nanoindentation and Cavitation-Induced Fragmentation Study of Primary Al3Zr Intermetallics Formed in Al Alloys
Year(s) Of Engagement Activity 2020
URL http://doi.org/10.1007/978-3-030-36408-3_23
 
Description Nonlinear helmholtz modelling of acoustic cavitation in water 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Nonlinear helmholtz modelling of acoustic cavitation in water at 27th International Congress on Sound and Vibration by C. Beckwith, G. Djambazov, K. Pericleous, C. Tonry, A. Priyadarshi, M. Khavari, I. Tzanakis, D. Eskin on 11-16 July 2021
Year(s) Of Engagement Activity 2021
URL https://iiav.org/content/archives_icsv_last/2021_icsv27/content/papers/papers/full_paper_228_2021041...
 
Description Novelis Europe - REALITY 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Meetings with Novelis and Brunel to formulate Recycled Aluminium through Innovative Technology (REALITY) project with Innovate UK.
Year(s) Of Engagement Activity 2017
 
Description Oral Presentation at International Conference on Materials Science and Engineering 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Isaac Chang: Oral presentation at International Conference on Materials Science and Engineering
Year(s) Of Engagement Activity 2019
 
Description Participation in National Hub Buisness Development Meeting 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Mark Jones Attendance and Participation in National Hub Buisness Development Meeting
Year(s) Of Engagement Activity 2020
 
Description Participation in Sustainable Industrial Manufacturing (SIM) Europe 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact The panel session moderated by Geoff Scamans (BCAST - LiME and CircularMetal) was hosted by Circulor, and discussed the following statement: "In an ideal industrial production future, recycled materials will replace all virgin materials and we will design and create products that are easily separated, collected and recycled". The reality is that the details of Europe's industrial transition to a circular and low-carbon economy are only just emerging, and the dream of "full circularity" is a long way off. The panel explored what it will take to move from vision to reality.
Year(s) Of Engagement Activity 2022
URL https://sustainableindustrialmanufacturing.com/content-images/main/SIM_ConferenceProg_June2022-3.pdf
 
Description Presence of LiME stand at Manufacturing 2075 conference 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Having a LiME stand at Manufacturing 2075 conference to showcase our research to the wider academic and industrial audience.
Year(s) Of Engagement Activity 2016
 
Description Presence of LiME stand at the Cenex Low Carbon Vehicle Conference 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Having a LiME stand at the Cenex Low Carbon Vehicle Conference to showcase our research to the predominant wider automotive and industrial audience.
Year(s) Of Engagement Activity 2016,2017,2018
 
Description RACEForm project articles - 2017 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Media engagements in relation to the RACEForm project:
http://www.4-traders.com/MERCIA-TECHNOLOGIES-PLC-19157169/news/Mercia-Technologies-Impression-Technologies-secures-grant-funding-25562937/
http://www.thebusinessdesk.com/westmidlands/news/2012358-10m-funding-allows-automotive-supplier-press-patented-technology
https://www.insidermedia.com/insider/national/Cash-injection-for-automotive-consortium
http://www.lse.co.uk/AllNews.asp?code=rl4zu9jy&headline=Mercia_Technologies_Investee_Wins_Research_Project_Funding
https://www.londonstockexchange.com/exchange/news/alliance-news/detail/1511517835026042700.html
http://www.morningstar.co.uk/uk/news/AN_1511517835026042700/mercia-technologies-investee-wins-research-project-funding.aspx
https://www.milanofinanza.it/404-pagina-non-disponibile
http://www.classeditori.com/dettaglionotizia.asp?id=201711241556001931
https://www.financedigest.com/impression-technologies-secures-grant-funding-with-tier-1-automotive-partners.html
http://www.downtowninbusiness.com/impression-technologies-secures-grant-funding-tier-1-automotive-partners/
http://advis.ru/php/view_news.php?id=3ADDFAB7-183F-D445-B3CF-0802C866DA4E
https://www.globalbankingandfinance.com/impression-technologies-secures-grant-funding-with-tier-1-automotive-partners/
http://www.4-traders.com/news/Brunel-University-Consortium-bags-9-6m-for-rapid-aluminium-cost-effective-forming--25592459/
http://www.brunel.ac.uk/news-and-events/news/articles/Consortium-bags-9.6m-for-rapid-aluminium-cost-effective-forming
https://www.engineerlive.com/content/new-process-creating-complex-panels
http://www.scci.org.uk/2017/12/impression-technologies-secures-grant-funding-with-tier-1-automotive-partners/
https://www.theengineer.co.uk/raceform-aluminium-project-funding/
https://aluminiuminsider.com/british-tech-consortium-garners-9-6-mm-develop-process-economical-rapid-forming-aluminium-alloys/
http://lookwestlondon.com/brunel-wins-lightweight-aluminium-cash/
https://worldindustrialreporter.com/raceform-validates-new-lightweight-aluminum-alloy-production/
http://i.gasgoo.com/news/detail/580059.html
http://news.sxxw.net/qiche/html/201714/12/3338297.html
http://www.xincailiao.com/news/news_detail.aspx?id=114409
http://www.buycar.cn/kanche/20171214/929622_1.html
http://www.aluminiumtoday.com/news/view/ultra-light-car-parts
https://www.metalbulletin.com/Article/3717668/STEEL-VS-AL-Brunel-JLR-combine-on-lightweight-car-parts.html
https://www.theengineer.co.uk/raceform-aluminium-project-funding/
https://aluminiuminsider.com/british-tech-consortium-garners-9-6-mm-develop-process-economical-rapid-forming-aluminium-alloys/
Year(s) Of Engagement Activity 2017
 
Description REALCAR project articles - 2016 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Articles on the JLR Realcar collaboration.
http://automotivelogistics.media/intelligence/jlr-gets-real-recycled-aluminium-loops
Year(s) Of Engagement Activity 2016
URL http://automotivelogistics.media/intelligence/jlr-gets-real-recycled-aluminium-loops
 
Description Recycled AA6111 aluminium alloy manufactured by melt conditioned direct chill casting and thermomechanical forming processes 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at International Conference on Materials Science and Engineering 2019 16-18 Sept 2019 by I Chang.
Title: Recycled AA6111 aluminium alloy manufactured by melt conditioned direct chill casting and thermomechanical forming processes
Year(s) Of Engagement Activity 2020
URL https://www.materialsconferenceaustralia.com/
 
Description SALEMA workshop: Driving sustainable aluminium: recycling and critical raw materials for aluminium alloys in e-mobility 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact The SALEMA project aims to reduce the dependency on critical raw materials (CRMs) such as silicon and magnesium in aluminium alloys. One objective is to develop new aluminium alloys that minimise the primary sourcing of CRMs, by maximising their sourcing from scrap metal recycling. The suitability and performance of these new aluminium alloys will be evaluated for three different manufacturing processes (high pressure die casting, extrusion and stamping) that will be used to produce five demonstrators representing different e-vehicles parts. The integration of scrap metal recycling is essential to create a sustainable circular economy, serving as a reliable source for high-quality alloy.
The workshop addressed the challenges and opportunities of CRMs reduction for aluminium alloys in e-vehicles. Synergies with other EU projects were analysed.
Year(s) Of Engagement Activity 2022
URL https://european-aluminium.eu/wp-content/uploads/2022/11/salemaworkshop04-11-22-.pdf
 
Description Sapa 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Meetings from the request of Sapa to trial the high shear melt conditioning equipment. This was integrated with the industrial scale conventional vertical drop type multi-strand DC caster at the SAPA facility in Belgium to produce melt conditioned billets of 206 mm diameter and 7metre length. The objective was to produce billets with refined microstructure without using Ti and B based grain refiners and improve the intermetallic phase formation and distribution in a specifically developed 6000 series SAPA aluminium alloy, for easier downstream thermo-mechanical processing, and ultimately enhanced mechanical properties of finished products. After successful results from the first trial, the SAPA collaboration now focuses on MC-DC casting trials with deliberate increase of Fe/Mn content, in order to produce good quality billets with higher Fe tolerance.
Year(s) Of Engagement Activity 2015,2016,2017,2018,2019
 
Description Seminar: STRUCTURE AND PROPERTIES OF MULTICOMPONENT HIGH-ENTROPY CANTOR ALLOYS 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Postgraduate students
Results and Impact Seminar: STRUCTURE AND PROPERTIES OF MULTICOMPONENT HIGH-ENTROPY CANTOR ALLOYS by Professor Brian Cantor. 5 February 2020.
Year(s) Of Engagement Activity 2020
 
Description Seminar: Steel in a circular economy: Global implications of a green shift in China 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Postgraduate students
Results and Impact Seminar: Steel in a circular economy: Global implications of a green shift in China given by Dr Alvaro Calzadilla - UCL
Year(s) Of Engagement Activity 2020
 
Description Seminar: The Transition to a Circular Economy: The Case of Metals 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Postgraduate students
Results and Impact Seminar: The Transition to a Circular Economy: The Case of Metals given by Professor Raimund Bleischwitz, UCL. 4 March 2020
Year(s) Of Engagement Activity 2020
 
Description Shaping the Future of Metallurgy with Research: Advanced Metal Casting Centre at Brunel - YouTube 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact Youtube video by Brunel University London promoting LiME's research and the AMCC facility
Year(s) Of Engagement Activity 2007,2016
URL https://www.youtube.com/watch?v=naxc-QPCIK8
 
Description Si Solutions in Al-rich FeAl Intermetallic Compounds from First-principles Calculations 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Si Solutions in Al-rich FeAl Intermetallic Compounds from First-principles Calculations. Presentation at NME 2020 6-9 December 2020
Year(s) Of Engagement Activity 2020
URL https://opensz.oss-cn-beijing.aliyuncs.com/NME2020/file/NME%26CMA2020%20Conference%20Program.pdf
 
Description Si Solutions in Al-rich FeAl Intermetallic Compounds from Firstprinciples Calculations 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation at NME2020&CMA2020, 6-9 Dec 2020 by CM Fang. Title: Si Solutions in Al-rich FeAl Intermetallic Compounds from Firstprinciples Calculations
Year(s) Of Engagement Activity 2020
 
Description Slovenia Government Office for Development and European Cohesion Policy 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Meeting at Brunel and in Slovenia with their Government Office for Development and European Cohesion Policy to support their industry, government and university development of their new R&D scale up facility, similar to our AMCC and AMPC.
Year(s) Of Engagement Activity 2018
 
Description Stirling Media's UK Manufacturing Industry Review 
Form Of Engagement Activity A press release, press conference or response to a media enquiry/interview
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Media (as a channel to the public)
Results and Impact Interview about the LiME programme for Stirling Media's UK Manufacturing Industry Review
Year(s) Of Engagement Activity 2018,2019
 
Description Strengthening aluminium alloys under as-cast condition for high pressure die casting 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Strengthening aluminium alloys under as-cast condition for high pressure die casting at Materials Week 2021 on 7-9 September 2021 by X. Zhu, X. Dong, S. Ji
Year(s) Of Engagement Activity 2021
URL https://dgm.de/materialsweek/
 
Description Strengthening aluminium alloys under as-cast condition for high pressure die casting 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Strengthening aluminium alloys under as-cast condition for high pressure die casting at 2nd Advanced Materials Science World Congress 2021 by X. Zhu, X. Dong, S. Ji on 14-15 June 2021
Year(s) Of Engagement Activity 2021
URL https://www.mdpi.com/journal/materials/events/12513
 
Description Swiss Federal Laboratory's Visit 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact A visit by Dr Marcello Conte and Dr Nishil Malde of the Swiss Federal Laboratories for Materials Science and Technology, Laboratory for Mechanics of Materials and Nanostructures, the visit was followed by a Seminar.
Year(s) Of Engagement Activity 2016