LIGHT ALLOYS TOWARDS ENVIRONMETALLY SUSTAINABLE TRANSPORT: 2nd GENERATION SOLUTIONS FOR ADVANCED METALLIC SYSTEMS (LATEST2)

To avoid global warming and our unsustainable dependence on fossil fuels, the UK's CO2 emissions are recommended to be reduced by 80% from current levels by 2050. Aerospace and automotive manufacturing are critical to the UK economy, with a turnover of 30 billion and employing some 600,000 worker. Applications for light alloys within the transport sector are projected to double in the next decade. However, the properties and cost of current light alloy materials, and the associated manufacturing processes, are already inhibiting progress. Polymer composites are too expensive for body structures in large volume vehicle production and difficult to recycle. First generation, with a high level of recycling, full light alloy aluminium and magnesium vehicles in production are cheaper and give similar weight savings (~ 40%) and life cycle CO2 footprint to low cost composites. Computer-based design tools are also playing an increasing role in industry and allow, as never before, the optimisation of complex component architectures for increased mass efficiency. High performance alloys are still dominant in aeroengine applications and will provide ~ 30% of the structural components of future aircraft designs, where they will have to be increasingly produced in more intricate component shapes and interfaced with composite materials.To achieve further weight reductions, a second generation of higher performance light alloy design solutions are thus required that perform reliably in service, are recyclable, and have more complex product forms - produced with lower cost, energy efficient, manufacturing processes. With design optimisation, and by combining the best attributes of advanced high strength Al and Mg alloys with composites, laminates, and cheaper steel products, it will be possible to produce step change in performance with cost-effective, highly mass efficient, multi-material structures.This roadmap presents many challenges to the materials community, with research urgently required address the science necessary to solve the following critical issues: How do we make more complex shapes in higher performance lower formability materials, while achieving the required internal microstructure, texture, surface finish and, hence, service and cosmetic properties, and with lower energy requirements? How do we join different materials, such as aluminium and magnesium, with composites, laminates, and steel to produce hybrid materials and more mass efficient cost-effective designs? How do we protect such multi-material structures, and their interfaces against corrosion and environmental degradation?Examples of the many scientific challenges that require immediate attention include, how can we: (i) capture the influence of a materials deformation mechanisms, microstructure and texture on formability, thus allowing computer models to be used to rapidly optimise forming for difficult alloys in terms of component shape and energy requirements; (ii) predict and control detrimental interfacial reactions in dissimilar joints; (iii) take advantage of innovative ideas, like using lasers to 'draw on' more formable microstructures in panels, where it is needed; (v) use smart self healing coating technologies to protect new alloys and dissimilar joints in service, (vi) mitigate against the impact of contamination from recycling on growth of oxide barrier coating, etc.A high priority for the Programme is to help fill the skills gap in metallurgical and corrosion science, highlighted in the EPSRC Review of Materials Research (IMR2008), by training the globally competitive, multidisciplinary, and innovative materials engineers needed by UK manufacturing. The impact of the project will be enhanced by a professionally managed, strategic, research Programme and through promoting a high international profile of the research output, as well as by performing an advocacy role for materials engineering to the general public.

LATEST2 aims to underpin developments vital to the future of UK aerospace and automotive manufacturing. The research has been targeted to maximise impact by providing a step advance in the science base required in the move towards more efficient products, which is essential to maintain global competitiveness. The Team has a strong track record in managing the dissemination of research outcomes to a wide range of user groups, as exemplified by the successful LATEST Portfolio Partnership. Industrial beneficiaries of the research include aerospace and automotive manufacturing and its full supply chain (e.g. Airbus, Rolls Royce, Meridian, Jaguar-LR, Novelis, MEL, Alcan etc). There are also important indirect benefits in terms of maintaining the knowledge base, reducing industry's CO2 footprint, sustainability, and training. Training of the next generation of materials engineers is of particular importance due to a skills shortage in metallurgy and will be enhanced by alignment with the Sheffield-Manchester DTC in metallic materials. The research will include topics that are close to commercial exploitation, e.g. new joining technologies for dissimilar materials, novel treatments for control of cosmetic corrosion etc, as well as more fundamental work leading to longer term commercialisation, e.g. modelling tools for forming light alloys and predicting joint performance in multi-material designs. Research outputs will provide 'quality of life' benefits to the public through improved environmental performance of next-generation vehicles. Ensuring global competiveness in the automotive and aerospace manufacturing sectors is fundamental to future employment and wealth creation. LATEST2 further envisages collaborations with regional bodies (e.g. NWDA) to influence policy on sustainability. LATEST2 will develop a broad range of access points to allow maximum engagement at all levels, with general communication promoted through a vibrant web site, newsletters and press releases. Engagement with Industry will be through workshops, an annual open conference to showcase results, international conferences, trade journals and networking with research organisations, companies, and trade bodies (IOM3, NAMTEC and AlFed. We will further fund secondments to and from industry and leading academic establishments. A key goal is to improve awareness at schools and with the general public. This will be realised by engagement through specialist organisations, such as the Nuffield Trust and Industrial Trust, as well as summer schools, internships and science festivals, to broaden awareness of the subject and attract the highest calibre of students. We will also develop resources for teachers and provide specialist science communication training for our PhD students to expand the breadth of our public engagement. LATEST2 is further committed to the promotion of sustainable materials for transportation through public lectures and museum exhibits. We have a positive relationship with the Manchester Museum of Science and Industry, where we currently have a permanent display and plan to deliver interactive sessions specifically on light alloys for sport, transport and sustainability. As part of our plans for dissemination we will create a web database to manage knowledge for academia, industry and the public, to share information on developments in the field, training, and events, as well as a repository for reports and PhD theses etc. We will maintain this system for five years post-completion, ensuring the maximum accessibility. Implementation of the impact plan will be managed by a professional Project Manger, under direction of the Management Group, supported by an outreach officer. A role of the Project Manger will be to ensure that the legal framework is in place to protect IPR, and pave the way for exploiting new discoveries. We will also obtain feedback to measure success of the impact plan by tracking delivery against targets.