Brunel University - Equipment Account
Lead Research Organisation:
Brunel University London
Department Name: Mechanical and Aerospace Engineering
Abstract
Over the last few years EPSRC has invested significantly in metal casting research at Brunel's research institute BCAST, notably in the EPSRC Centre - LiME (£6M) in 2010, the TARF-LCV programme (£4.2M) in 2011 and other responsive mode projects (£1M). Both the LiME and TARF-LCV programmes were founded on our long-term vision for full metal circulation: that the global demand for metallic materials should be met by a full circulation of secondary metals with only limited addition of primary metals each year, which can be achieved by effective reuse, remanufacture, closed-loop recycling and effective recovery of secondary metals. This full metal circulation represents a paradigm shift for metallurgical science, manufacturing technology and the industrial landscape. LiME was founded to provide a solid foundation for full metal circulation. Although substantial progress [3] has been made in the fundamental understanding of heterogeneous nucleation, developing new metallic materials and advancing casting technologies under both LiME and TARF-LCV the industrial adoption and exploitation of the research output has been constrained, mainly due to the lack of scale-up facilities to take the lab-proven concepts and processing technologies to a suitable level, at which industrial companies are willing to take the risk to conduct industrial trials.
We propose to establish a unique national scale-up facility for light metal casting research to be hosted in the Advanced Metal Casting Centre (AMCC) at Brunel University. AMCC aims to bridge the gap between fundamental research and industrial applications. Together with the EPSRC Centre for Innovative Manufacturing in Liquid Metal Engineering (LiME for short), the AMCC will provide high performance light alloys, resource efficient casting technologies and component innovations to meet the long- and mid-term needs of the automotive industry. To set up the AMCC we are requesting £3.9M from EPSRC to match a £2.5M investment by Brunel University for capital equipment and infrastructure and £3.15M cash and £3.36M in-kind contributions from our industrial partners for the initial research projects. The scale-up facilities will be installed in a purpose-built 1000m2 laboratory complete with power, water and gas supply. The new facilities will enable and enhance our established research capability in many different areas, such as liquid metal engineering, alloy development, processing technologies and component innovation. We will work closely with the automotive industry and its supply chain.
We propose to establish a unique national scale-up facility for light metal casting research to be hosted in the Advanced Metal Casting Centre (AMCC) at Brunel University. AMCC aims to bridge the gap between fundamental research and industrial applications. Together with the EPSRC Centre for Innovative Manufacturing in Liquid Metal Engineering (LiME for short), the AMCC will provide high performance light alloys, resource efficient casting technologies and component innovations to meet the long- and mid-term needs of the automotive industry. To set up the AMCC we are requesting £3.9M from EPSRC to match a £2.5M investment by Brunel University for capital equipment and infrastructure and £3.15M cash and £3.36M in-kind contributions from our industrial partners for the initial research projects. The scale-up facilities will be installed in a purpose-built 1000m2 laboratory complete with power, water and gas supply. The new facilities will enable and enhance our established research capability in many different areas, such as liquid metal engineering, alloy development, processing technologies and component innovation. We will work closely with the automotive industry and its supply chain.
Planned Impact
The Advanced Metal Casting Centre (AMCC) will provide state-of-the-art scale-up facilities for advanced light metal casting, to exploit world leading research and development in resource efficient processing of high performance alloys. The AMCC builds directly on the EPSRC's strategic investment in the Centre for Innovative Manufacturing in Liquid Metal Engineering (LiME for short) to enhance the UK's capability in this important technological area. The academic impact of the AMCC and LiME comes from both the research activities and their direct application using the scaled-up casting facilities. The proposed scale-up facilities are unique in the UK, and cannot be found in any other UK university or within the TSB supported High Value Manufacturing Catapult Centres. These unique facilities will be made open access to the UK solidification and casting community, to strengthen solidification research in the UK and its international standing. The academic impact of the AMCC and LiME also derives from its ground-breaking research activities. The scientific deliverables from the AMCC and LiME represent major advances in solidification science, physical metallurgy, high performance metallic materials and resource efficient casting technologies.
The key focus of the AMCC facilities and R&D activities is on transportation but specifically its initial impact will be on the UK automotive industry and its supply chain and then the wider transportation industry. Specifically, the automotive industry will benefit because: (1) for the first time the UK automotive industry and its supply chain will have direct access to a dedicated R&D centre for the development of resource efficient processing technologies for the production of high performance metallic materials; (2) the AMCC together with LiME will be a sandpit for the UK automotive industry and its supply chain; (3) the AMCC will work closely with the automotive OEMs to rebuild UK's domestic supply chain which has been hollowed-out in last 30 years; (4) the shortened lead time from technology concept to industrial production; (5) advanced manufacturing technologies to provide technological advantages over competitors; (6) sustainable light weight high performance metallic materials with reduced cost; and (7) improved sustainability due to reduced CO2 emissions, conservation of natural resources and consequently reduced environmental impact. The overall benefits to the UK automotive industry and its supply chain from the AMCC will be profound, and will make a major contribution to rebalancing the UK economy.
The potential environmental sustainability impact of the proposed scale-up facilities and enabled research activities in the AMCC and LiME is profound as the research and industrial application outputs will have a dramatic influence on the practicality of curbing the carbon emissions from the global automotive fleet in a timely manner. 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.
Training people has been a key focus of the AMCC as it has been for LiME in support of EPSRC's Delivery Plan. There will be over 10 early-career academics and senior research fellows, 40 post-doctoral researchers and PhD research students being trained in the AMCC and LiME research programme, and some of them will become the future leaders in solidification and casting research. The AMCC will become the training ground for skilled engineers for the UK automotive OEMs and their supply chain. Over 30 industrial engineers from automotive OEMs and their supply chain will be directly working in the AMCC (either full time or part time) to participate or support the AMCC research programme. Special training programmes will be developed to refresh and upgrade their metallurgical knowledge, especially in solidification science and casting technologies.
The key focus of the AMCC facilities and R&D activities is on transportation but specifically its initial impact will be on the UK automotive industry and its supply chain and then the wider transportation industry. Specifically, the automotive industry will benefit because: (1) for the first time the UK automotive industry and its supply chain will have direct access to a dedicated R&D centre for the development of resource efficient processing technologies for the production of high performance metallic materials; (2) the AMCC together with LiME will be a sandpit for the UK automotive industry and its supply chain; (3) the AMCC will work closely with the automotive OEMs to rebuild UK's domestic supply chain which has been hollowed-out in last 30 years; (4) the shortened lead time from technology concept to industrial production; (5) advanced manufacturing technologies to provide technological advantages over competitors; (6) sustainable light weight high performance metallic materials with reduced cost; and (7) improved sustainability due to reduced CO2 emissions, conservation of natural resources and consequently reduced environmental impact. The overall benefits to the UK automotive industry and its supply chain from the AMCC will be profound, and will make a major contribution to rebalancing the UK economy.
The potential environmental sustainability impact of the proposed scale-up facilities and enabled research activities in the AMCC and LiME is profound as the research and industrial application outputs will have a dramatic influence on the practicality of curbing the carbon emissions from the global automotive fleet in a timely manner. 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.
Training people has been a key focus of the AMCC as it has been for LiME in support of EPSRC's Delivery Plan. There will be over 10 early-career academics and senior research fellows, 40 post-doctoral researchers and PhD research students being trained in the AMCC and LiME research programme, and some of them will become the future leaders in solidification and casting research. The AMCC will become the training ground for skilled engineers for the UK automotive OEMs and their supply chain. Over 30 industrial engineers from automotive OEMs and their supply chain will be directly working in the AMCC (either full time or part time) to participate or support the AMCC research programme. Special training programmes will be developed to refresh and upgrade their metallurgical knowledge, especially in solidification science and casting technologies.
Organisations
- Brunel University London (Lead Research Organisation)
- Impression Technologies Ltd (Collaboration)
- Lighthouse Systems Ltd (Collaboration)
- Jaguar Land Rover Automotive PLC (Collaboration)
- Grainger & Worrall Limited (Collaboration)
- University of Warwick (Collaboration)
- Volkswagen (Collaboration)
- Innoval Technology (Collaboration)
- Huttenes-Albertus UK Ltd (Collaboration)
- Luxfer Gas Cylinders (Collaboration)
- Automotive Council UK (Collaboration)
- Novelis (Collaboration)
- Autotech Engineering R&D UK Limited (Collaboration)
- Nissan Motor Manufacturing Ltd (Collaboration)
- T. A. Savery & Co Limited (Collaboration)
- UNIVERSITY OF STRATHCLYDE (Collaboration)
- Norton Aluminium Ltd (Collaboration)
- Gordon Murray Design Ltd (Collaboration)
- Zero Carbon Futures Ltd (Collaboration)
- IMPERIAL COLLEGE LONDON (Collaboration)
- Sarginsons Industries Ltd (Collaboration)
- Axion Recycling Ltd (Collaboration)
- Magna International (Collaboration)
- Engineering and Physical Sciences Research Council (EPSRC) (Collaboration)
- Constellium (Collaboration)
- Bentley Motors (Collaboration)
- GKN (Collaboration)
- Oskar Frech GmbH + Co. KG (Collaboration)
- Frog Bikes Limited (Collaboration)
- Powdertech (Collaboration)
People |
ORCID iD |
| Z Fan (Principal Investigator) |
Publications
Zhang X
(2019)
Corrosion behaviour of AA6082 Al-Mg-Si alloy extrusion: The influence of quench cooling rate
in Corrosion Science
Amirkhanlou S
(2019)
Casting lightweight stiff aluminum alloys: a review
in Critical Reviews in Solid State and Materials Sciences
Amirkhanlou S
(2019)
A review on high stiffness aluminum-based composites and bimetallics
in Critical Reviews in Solid State and Materials Sciences
Lordan E
(2018)
Effective Degassing for Reduced Variability in High-Pressure Die Casting Performance
in JOM
Dong X
(2019)
High strength and ductility aluminium alloy processed by high pressure die casting
in Journal of Alloys and Compounds
Dong X
(2019)
Effect of super vacuum assisted high pressure die casting on the repeatability of mechanical properties of Al-Si-Mg-Mn die-cast alloys
in Journal of Materials Processing Technology
Zhu X
(2018)
The effects of varying Mg and Si levels on the microstructural inhomogeneity and eutectic Mg2Si morphology in die-cast Al-Mg-Si alloys
in Journal of Materials Science
Zhu X
(2018)
Strengthening die-cast Al-Mg and Al-Mg-Mn alloys with Fe as a beneficial element
in Materials Science and Engineering: A
Ji S
(2019)
Atomic structure and interface chemistry in a high-stiffness and high-strength Al-Si-Mg/TiB2 nanocomposite
in Materials Science and Engineering: A
| Description | As this is an equipment grant it does not fund research directly. However, research which makes use of the equipment has resulted in the development of low cost extrudable aluminium alloys for automotive applications with the strength of more costly non extrudable aerospace alloys, A new processing technology such as melt-conditioned DC Casting and Twin-roll Casting, and new and strong links with industrial companies. The AMCC facilities has played a vital role in recent years in developing electrical vehicle structures with the financial support from Innovate UK and APC. We have sent he new generation of integrated battery enclosure being developed and collaboration between Constellium and BCAST with other industrial partners. Another new development, is the further increase of strength of the new alloys we developed earlier and this alloy has been part of the battery enclosure. |
| Exploitation Route | We are working with our industrial partners who have commercialised the high strength alloys. These alloys have been applied in structural automotive applications such as crash management systems and together with our partners we are developing battery boxes for electric vehicles. Leveraged Innovate UK funding has led to our partner Gordon Murray Design making available an Aluminium version of their I-Stream technology for light weight vehicle frames. In addition, we have been pushing for commercialisation of our new processing technologies with our industrial partners and other potential users. We have been working with Sarginsons (low pressure die casting company) to develop the low pressure die casting facility for production of Jaguar Land Rover components and through this collaboration the low pressure die casting facility now is in good operational condition for further R&D usage. The Low pressure die casting facility has been utilised to support Nissan for Engine components and testing the fast degassing technology through High shear. The low pressure die casting facility has been the work horse for the ATI funded aerospace casting project and which has validated the entry use of Aluminium casting in aerospace industry. |
| Sectors | Aerospace, Defence and Marine,Construction,Environment,Manufacturing, including Industrial Biotechology,Transport |
| Description | As this is an equipment grant it does not fund research directly. However, as a result of the creation of the AMCC, which houses the equipment, we have established a formal partnership with Constellium, known as the Constellium University Technology Centre. Research being carried out on the development of high strength extrusion alloys, which uses the equipment, has allowed the UTC to create prototypes of automotive components at an accelerated rate within vehicle design cycles. Constellium have won a number of commercial orders on the basis of the high strength extrusion alloy and their innovative designs. Constellium have also placed their R&D centre for automotive structures at Brunel to accelerate impact. Constellium are considering on-shoring a manufacturing facility. On the basis of our work and the facilities, we have attracted several new leveraged Innovate UK and automotive propulsion centre research programmes. These programmes have led to the development of new lightweight vehicle frames and crash management systems. We have also developed a number of new closed loop recyclable alloys for extrusion and casting processes. As a result of the success of the Advanced Metals Casting Centre, we have established a second phase of our up-scaling facilities known as the Advanced Metals Processing Centre with funding from the HEFCE UKRPIF. As a national scaling up facility The AMCC equipment has become an integral part of UK R&D capability for supporting industrial R&D particularly the automotive and aerospace industries. |
| Sector | Aerospace, Defence and Marine,Manufacturing, including Industrial Biotechology,Transport |
| Impact Types | Economic |
| Description | "Grain refiner technology" for lightweight magnesium alloys - iCURE |
| Amount | £15,000 (GBP) |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 09/2017 |
| End | 12/2018 |
| Description | (AMCC2) Advanced Metals Casting Centre Phase II |
| Amount | £15,000,000 (GBP) |
| Organisation | Higher Education Funding Council for England |
| Sector | Public |
| Country | United Kingdom |
| Start | 06/2015 |
| End | 06/2017 |
| Description | (LEVEL-UP) - Protocols and Strategies for extending the useful Life of major capital investments and Large Industrial Equipment |
| Amount | € 17,039,855 (EUR) |
| Funding ID | 869991 |
| Organisation | European Commission |
| Sector | Public |
| Country | European Union (EU) |
| Start | 10/2019 |
| End | 09/2023 |
| Description | (LightMe) - An Open Innovation Ecosystem for upscaling production processes of lightweight metal alloys composites |
| Amount | € 12,943,298 (EUR) |
| Funding ID | 814552 |
| Organisation | European Commission |
| Sector | Public |
| Country | European Union (EU) |
| Start | 01/2019 |
| End | 12/2022 |
| Description | Advanced Propulsion Centre (APC) Wave 7: RACEForm |
| Amount | £860,028 (GBP) |
| Funding ID | 113153 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 11/2017 |
| End | 04/2020 |
| Description | Advanced Propulsion Centre 6 - CHAMELEON |
| Amount | £558,595 (GBP) |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 06/2017 |
| End | 05/2019 |
| Description | Alliance Casting European Development Centre (ACE-DC) |
| Amount | £781,245 (GBP) |
| Funding ID | 113116 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 06/2017 |
| End | 11/2020 |
| Description | Aluminium Alloy Development using TRC |
| Amount | £15,947 (GBP) |
| Organisation | Mahle Engine Systems UK Ltd |
| Sector | Private |
| Country | United Kingdom |
| Start | 06/2019 |
| End | 06/2019 |
| Description | Aluminium Carbon Fibre Hybrid Structures (CAAHS) |
| Amount | £1,857,474 (GBP) |
| Funding ID | 102634 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 09/2016 |
| End | 08/2018 |
| Description | Aluminium Intensive Vehicle Enclosure (ALIVE) |
| Amount | £1,261,460 (GBP) |
| Organisation | Advanced Propulsion Centre |
| Sector | Charity/Non Profit |
| Country | United Kingdom |
| Start | 09/2020 |
| End | 08/2023 |
| Description | Aluminium Reduced Cost Hybrid Parts (ARCH) |
| Amount | £277,914 (GBP) |
| Funding ID | 104418 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 09/2018 |
| End | 02/2021 |
| Description | Aluminium for Ultra Low Emission Vehicles |
| Amount | £752,451 (GBP) |
| Funding ID | 104324 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 07/2018 |
| End | 06/2020 |
| Description | Carbon Aluminium Automotive Hybrid Structures (CAAHS) |
| Amount | £699,358 (GBP) |
| Funding ID | 102634 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 09/2016 |
| End | 08/2018 |
| Description | Casting Integrity of High Pressure Die Castings - Studentship Ewan Lordan |
| Amount | £83,296 (GBP) |
| Funding ID | 2043200 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 10/2017 |
| End | 09/2022 |
| Description | Casting Integrity of High Pressure Die Castings - Studentship Ewan Lordan |
| Amount | £42,840 (GBP) |
| Organisation | Jaguar Land Rover Automotive PLC |
| Department | Jaguar Land Rover |
| Sector | Private |
| Country | United Kingdom |
| Start | 10/2017 |
| End | 03/2021 |
| Description | Constellium - AMCC Programme - Research Fellows |
| Amount | £787,567 (GBP) |
| Organisation | Constellium |
| Sector | Private |
| Country | France |
| Start | 09/2014 |
| End | 12/2018 |
| Description | Constellium - Development of Heat Treatable Ultra-High Strength Al Alloys for Automotive Application - iCASE Studentship David Makuyana |
| Amount | £27,800 (GBP) |
| Organisation | Constellium |
| Sector | Private |
| Country | France |
| Start | 02/2018 |
| End | 01/2022 |
| Description | Constellium - LiME Sponsored Fellowship |
| Amount | £510,000 (GBP) |
| Organisation | Constellium |
| Sector | Private |
| Country | France |
| Start | 01/2016 |
| End | 12/2018 |
| Description | Constellium - Novel processing of 6xxx alloys for automotive applications - iCASE Studentship Chrysoula Tzileroglou |
| Amount | £27,800 (GBP) |
| Organisation | Constellium |
| Sector | Private |
| Country | France |
| Start | 10/2017 |
| End | 09/2022 |
| Description | EPSRC - Development of Heat Treatable Ultra-High Strength Al Alloys for Automotive Application - iCASE Studentship David Makuyana |
| Amount | £83,296 (GBP) |
| Funding ID | 2043889 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 02/2018 |
| End | 01/2022 |
| Description | EPSRC - iCASE Studentship - Hamza Youssef |
| Amount | £81,430 (GBP) |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 10/2017 |
| End | 03/2021 |
| Description | EPSRC Responsive Mode: High Reliability Interconnects: New Methodologies for Pb-free Solders |
| Amount | £1,299,714 (GBP) |
| Funding ID | EP/R018863/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 07/2018 |
| End | 06/2021 |
| Description | Frog Bikes Innovate UK Manufacturing and materials application |
| Amount | £239,997 (GBP) |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 07/2017 |
| End | 03/2019 |
| Description | Fundamental study of the TiB2 -a Al nucleation process |
| Amount | £356,395 (GBP) |
| Organisation | MQP Ltd |
| Sector | Private |
| Country | United Kingdom |
| Start | 01/2020 |
| End | 12/2021 |
| Description | Future Metallurgy Centre |
| Amount | £16,000,000 (GBP) |
| Funding ID | Future Metallurgy Centre |
| Organisation | United Kingdom Research and Innovation |
| Department | Research England |
| Sector | Public |
| Country | United Kingdom |
| Start | 04/2020 |
| End | 03/2021 |
| 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 | High Performance Magnesium cylinder |
| Amount | £205,965 (GBP) |
| Funding ID | HPMaC |
| Organisation | Husqvarna Group |
| 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 |
| End | 01/2021 |
| Description | ICASE Studentship - V de Stefano |
| Amount | £27,765 (GBP) |
| Organisation | Constellium |
| Sector | Private |
| Country | France |
| Start | 02/2019 |
| End | 01/2023 |
| Description | Integrated Computational Process Engineering with focus on Aluminium Extrusion - student Ross Jarrett |
| Amount | £60,000 (GBP) |
| Organisation | Constellium |
| Department | Constellium UK Ltd |
| Sector | Private |
| Country | United Kingdom |
| Start | 05/2018 |
| End | 04/2022 |
| Description | Integrated Computational Process Engineering with focus on Aluminium Extrusion - student Ross Jarrett EPSRC iCASE sub code |
| Amount | £83,296 (GBP) |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 05/2018 |
| End | 04/2022 |
| Description | JLR - iCASE Studentship - Hamza Youssef |
| Amount | £42,840 (GBP) |
| Organisation | Jaguar Land Rover Automotive PLC |
| Department | Jaguar Land Rover |
| Sector | Private |
| Country | United Kingdom |
| Start | 10/2017 |
| End | 03/2021 |
| Description | JLR iCase Studentship - LUKE DORAN |
| Amount | £42,840 (GBP) |
| Funding ID | icase 18000094 |
| Organisation | Jaguar Land Rover Automotive PLC |
| Department | Jaguar Land Rover |
| Sector | Private |
| Country | United Kingdom |
| Start | 10/2019 |
| End | 09/2024 |
| Description | Leadfree Explosive Cord |
| Amount | £71,706 (GBP) |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 08/2015 |
| End | 01/2017 |
| 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 | 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 | 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 | 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 | PhD Studentship - Aluminium Alloy Development |
| 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 | 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 | 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 | 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 | 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 | 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 | Automotive Council |
| Organisation | Automotive Council UK |
| Country | United Kingdom |
| Sector | Charity/Non Profit |
| PI Contribution | Research and output engagement |
| Collaborator Contribution | In-kind. |
| Impact | Ongoing. |
| 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 | 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 | 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 | Innoval Technology Ltd |
| Organisation | Innoval Technology |
| Country | United Kingdom |
| Sector | Private |
| Start Year | 2006 |
| 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 | Jaguar and Land Rover |
| Organisation | Jaguar Land Rover Automotive PLC |
| Department | Jaguar Land Rover |
| Country | United Kingdom |
| Sector | Private |
| Start Year | 2006 |
| 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 | 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 | 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 | 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 | 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 |
| 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 | 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 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 | 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 | 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 | 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 | Arzyz Aluminum of Mexico |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Meetings with Arzyz Aluminum of Mexico to discuss research alignment with their production and commercialisation of aluminium alloys. |
| 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 | Birmingham City University |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Engagement with Birmingham City University to understand their Meridian Lightweight Technologies project and how we can support and potentially collaborate. |
| Year(s) Of Engagement Activity | 2017 |
| 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 | 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 | 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 | 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 | 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 | 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 | 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 | Georg Fischer |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Georg Fischer visit to discuss future research alignment and scale up trials for their lightweight castings. |
| Year(s) Of Engagement Activity | 2016,2017 |
| 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 | 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 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 | 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 | 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 | 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 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 | JH Lavender |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Meetings with JH Lavender to discuss our scale up capabilities of High Pressure Die Casting (HPDC) and Melt Conditioning. Discussions were also held regarding our alloy development. |
| Year(s) Of Engagement Activity | 2018 |
| 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 | 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 | Lizhong Group |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Lizhong Group meetings to discuss research alignment with their precision manufactured components for the automotive industry. |
| Year(s) Of Engagement Activity | 2017 |
| 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 | MQP Ltd |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Meetings with MQP Ltd to understand their aluminium products and explore collaboration opportunities. |
| Year(s) Of Engagement Activity | 2018 |
| 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 | Magontec visit |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Magontec visit to discuss future collaboration. |
| Year(s) Of Engagement Activity | 2017,2018 |
| 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 | Meridian Lightweight Technologies visit |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | To showcase our facilities and research with Meridian, who is the leading full service supplier of innovative magnesium die cast components and assemblies in the global automotive market. |
| Year(s) Of Engagement Activity | 2017 |
| Description | Milver Metals Company Ltd |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | Meetings with Milver Metals Company Ltd,the UK's largest producer of high-performance aluminium and copper alloys, to discuss R&D of materials and process development. |
| Year(s) Of Engagement Activity | 2018 |
| 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 | 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 | 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 | 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 | 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 | 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 | 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 |
| Description | Talum (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 Talum in (Slovenia) to potentially align our research with their aluminium extrusion materials development and casting. Further, Talum wanted to develop a scale up facility similar to our AMCC and AMPC, and wanted advise on how to do so. |
| Year(s) Of Engagement Activity | 2018 |
| Description | Tampere University of Technology (Finland) |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Other audiences |
| Results and Impact | Tampere University of Technology (Finland) visits to Brunel to discuss future collaboration. |
| Year(s) Of Engagement Activity | 2017,2018 |
| Description | The Aluminium Federation |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Meetings at Brunel to formulate a collaboration with The Aluminium Federation who process, trade and work with aluminium to foster innovation, promote best practice, develop skills and champion member interests. |
| Year(s) Of Engagement Activity | 2017,2018 |
| Description | The Future LiME Hub Annual Reports |
| Form Of Engagement Activity | A magazine, newsletter or online publication |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | Production of the LiME Annual Report to promote and disseminate the Hub's research activities. |
| Year(s) Of Engagement Activity | 2017,2018 |
| Description | The Future LiME Hub's Marketing Literature |
| Form Of Engagement Activity | A magazine, newsletter or online publication |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | Production of the LiME leaflet to act as a promotional tool to introduce the Hub's research activities. |
| Year(s) Of Engagement Activity | 2018,2019 |
| Description | The Institute of Materials, Mineral and Mining (IOM3). |
| 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 | Working with the IOM3 to define future direction of the Casting and Solidification Society. |
| Year(s) Of Engagement Activity | 2015,2016,2017,2018,2019 |
| Description | UK Automotive Investment Organisation |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | UK Automotive Investment Organisation visit to discuss alignment of LiME with the automotive industry. |
| Year(s) Of Engagement Activity | 2016,2017,2018 |
| Description | UK Manufacturing Forum: Driving forward the Priorities |
| 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 | UK Manufacturing Forum: Driving forward the Priorities, aligned with the Catapult network. |
| Year(s) Of Engagement Activity | 2018 |
| URL | https://www.eventbrite.co.uk/e/uk-manufacturing-forum-driving-forward-the-priorities-tickets-4628907... |
| Description | Visit from Chinalco to Brunel University London to form Strategic Partnership |
| Form Of Engagement Activity | A formal working group, expert panel or dialogue |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Policymakers/politicians |
| Results and Impact | Visit from Chinalco to Brunel University London to form Strategic Partnership. |
| Year(s) Of Engagement Activity | 2018 |
| Description | Visit to Univerza v Ljubljani (Slovenia) |
| 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 | Visit to Univerza v Ljubljani to work towards collaboration of fundamental research. They also required our attendance at a meeting to advise make a decision with their government about investment into their newly designed scale up research facility proposal with their industrial collaborators. They were using our scale up facilities to advise for the best approach forward. Dr Mark Jones and Dr Simon Butler presented invited lectures on 'BCAST Overview' - Dr Mark Jones and 'Latest Developments of Melt Conditioning (MC) Technology' |
| Year(s) Of Engagement Activity | 2018 |
| Description | Volkswagen |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | Volkswagen engagement at our Mg2018 conference hosted by LiME, leading to further meetings within Brunel and a future Melt Conditioned Twin Roll Casting (TRC) project for automotive thin strip magnesium material development and manufacture. Volkswagen are now collaborating with LiME on the development of their Mg alloy thin strip using our TRC processing with our Melt Conditioning technology. |
| Year(s) Of Engagement Activity | 2017,2018,2019 |
| Description | Work Experience Week |
| 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 | Schools |
| Results and Impact | Our week long school work experience programme provides older school aged students with the opportunity to gain an introduction and overview of the facilities, equipment and research that goes on within the Hub's program. |
| Year(s) Of Engagement Activity | 2015,2016,2017 |