Bcc-superalloys: Engineering Resilience to Extreme Environments
Lead Research Organisation:
University of Birmingham
Department Name: Metallurgy and Materials
Abstract
Nuclear fusion, Generation IV fission reactors and aerospace gas turbines are critical to our future energy generation and transportation. Their operation at high temperatures necessitates construction from a variety of advanced materials. In order to withstand these extreme environments materials require high melting points, high temperature strength and environmental resistance, and, for nuclear, irradiation resistance. There are strong environmental and economic incentives to yet further increase the temperature capability of the materials used, in order to improve efficiency to reduce fuel use, as well as for improve performance, design life and safety. However, while iterative improvements are being made year on year the temperature gains are becoming ever harder to realise. In this proposal a step change in temperature capability is sought by the realisation of a new class of body-centred-cubic (bcc, an atomic crystal structure) superalloys based on (1) Tungsten, (2) Titanium, and (3) Steel, for the extreme environments of nuclear fusion and gen IV fission reactors as well as aerospace gas turbine engines.
I will create a close network of industrial, national and international academic partners, that will enable translation of these advanced materials from concept through to scale-up. The collaborations will be split across the bcc-superalloys Work Packages: (WP1) Tungsten, bringing in Culham Centre for Fusion Energy (CCFE), and ANSTO Sydney, toward nuclear fusion and Gen IV fission; (WP2) Titanium, brining in TIMET and Rolls Royce, for aero-engines, as well as ETH Zurich for thin film based alloy discovery; (WP3) Steel, bringing in Rolls Royce, for gas/steam turbines, and the Max-Planck-Institut für Eisenforschung (Iron Research, MPIE) Dusseldorf for advanced characterisation and steels expertise.
Bcc superalloys comprise a metal matrix, where the atoms are arranged in a bcc crystal structure, which are reinforced by forming precipitates of high strength ordered-bcc intermetallic compounds (e.g. TiFe or NiAl). This has parallels to the strategy used in current face-centred-cubic (fcc) nickel-based superalloys. However, changing the base metal's crystal structure, and therefore also the reinforcing intermetallic compound, represents a fundamental redesign and necessitates the development of new understanding. The key advantage of using a bcc refractory-metal-, titanium-, or steel- based superalloy is their increased melting point(s), which give the possibility of increased operating temperatures, as well as greatly reduced cost for the case of steels. However, the change in crystal structure requires a fundamentally new design strategy. While the limited investigations into bcc superalloys have indicated that they have attractive strength, and creep resistance, they have been held back by their low ductility. During this fellowship, I will thoroughly investigate multiple ductilisation strategies on bcc-superalloys to advance their technology readiness level (TRL) and so remove the current barrier to their commercialisation.
Investigation of the systems will be undertaken by myself, the 2 Research Fellows (RF), technician, and PhD students allowed for by the programme, as well as staff time from the project partners (CCFE, TIMET, Rolls Royce, ANSTO, ETH Zurich and MPIE). The PhD students will undertake alloy development between: WP1 on Tungsten alloys 50% supported by CCFE, WP2 on Titanium, two students, one 50% by TIMET and a second 50% by Rolls Royce, with a fourth school funded by UoB on WP3 industrially supervised by Rolls Royce. The two 2 RFs and technician would work in alloy development and characterisation alongside these students, but also perform more detailed investigations, with one RF focussed on irradiation damage mechanisms, and the second RF on deformation mechanisms, both using advanced microscopy and micromechanics on which the related students would be progressively trained.
I will create a close network of industrial, national and international academic partners, that will enable translation of these advanced materials from concept through to scale-up. The collaborations will be split across the bcc-superalloys Work Packages: (WP1) Tungsten, bringing in Culham Centre for Fusion Energy (CCFE), and ANSTO Sydney, toward nuclear fusion and Gen IV fission; (WP2) Titanium, brining in TIMET and Rolls Royce, for aero-engines, as well as ETH Zurich for thin film based alloy discovery; (WP3) Steel, bringing in Rolls Royce, for gas/steam turbines, and the Max-Planck-Institut für Eisenforschung (Iron Research, MPIE) Dusseldorf for advanced characterisation and steels expertise.
Bcc superalloys comprise a metal matrix, where the atoms are arranged in a bcc crystal structure, which are reinforced by forming precipitates of high strength ordered-bcc intermetallic compounds (e.g. TiFe or NiAl). This has parallels to the strategy used in current face-centred-cubic (fcc) nickel-based superalloys. However, changing the base metal's crystal structure, and therefore also the reinforcing intermetallic compound, represents a fundamental redesign and necessitates the development of new understanding. The key advantage of using a bcc refractory-metal-, titanium-, or steel- based superalloy is their increased melting point(s), which give the possibility of increased operating temperatures, as well as greatly reduced cost for the case of steels. However, the change in crystal structure requires a fundamentally new design strategy. While the limited investigations into bcc superalloys have indicated that they have attractive strength, and creep resistance, they have been held back by their low ductility. During this fellowship, I will thoroughly investigate multiple ductilisation strategies on bcc-superalloys to advance their technology readiness level (TRL) and so remove the current barrier to their commercialisation.
Investigation of the systems will be undertaken by myself, the 2 Research Fellows (RF), technician, and PhD students allowed for by the programme, as well as staff time from the project partners (CCFE, TIMET, Rolls Royce, ANSTO, ETH Zurich and MPIE). The PhD students will undertake alloy development between: WP1 on Tungsten alloys 50% supported by CCFE, WP2 on Titanium, two students, one 50% by TIMET and a second 50% by Rolls Royce, with a fourth school funded by UoB on WP3 industrially supervised by Rolls Royce. The two 2 RFs and technician would work in alloy development and characterisation alongside these students, but also perform more detailed investigations, with one RF focussed on irradiation damage mechanisms, and the second RF on deformation mechanisms, both using advanced microscopy and micromechanics on which the related students would be progressively trained.
Planned Impact
This fellowship seeks significant improvements in the efficiencies of gas and steam turbines used for air transport and energy generation, and performance of nuclear fusion/fission reactors. Improvements in efficiency would reduce fuel consumption and polluting emissions alongside reducing the cost of air transport and energy, providing wide societal benefits. This research is aligned to the long-term research interests of key UK companies CCFE, Rolls-Royce and TIMET for whom it would offer significant competitive advantage, with concomitant creation of high value manufacturing jobs across the whole of the UK economy, rather than just in the south-east.
This research will be disseminated through peer review journal publications and conference presentations and through outreach to UK industry at workshops, IOM3 meetings and company visits. Quarterly meetings with Rolls-Royce and TIMET will ensure the steel/titanium alloys align with engineering and scale up requirements, and the progress of new tungsten alloys discussed with CCFE and EURO-Fusion partners.
Exploitable IP will be patented and licensed jointly with the industrial partners and through University of Birmingham Enterprise. For alloy development IP it is critical to involve industrial partners both at the end application (e.g. Rolls-Royce and CCFE) and primary production (e.g. TIMET). Firstly this is to demonstrate the need, secondly, to ensure that the innovative material can be produced in a practical and cost-competitive manner capable of displacing the existing materials. TIMET and Rolls-Royce have well established routes for the commercialisation of new materials and long-term cooperative agreements with UoB. Onward research grants (e.g. Innovate UK) will also be sought to support this academically, alongside further industry co-funded PhDs, leveraging government funds to deliver impact.
Another impact will be training of new materials engineers, through the promised PhD funding (UoB, CCFE, Rolls-Royce and TIMET) and MSc students. Metallurgists are in great demand from UK job creators (e.g. Firth Rixson, Tata, JLR, BMW-Mini, TIMET, Siemens, EDF, Safran, Hitachi, Airbus, etc, and Rolls-Royce), as well as UK government and infrastructure (rail, BAE systems, MOD, etc). This supply gap has been met by cross-training scientists/engineers from other disciplines and by immigration, which given the UK's recent societal shift there is a need for the UK to internally grow highly qualified engineers.
Throughout the fellowship the research will regularly be disseminated through peer reviewed papers toward high impact journals. The work will also be presented at the major international conferences in the field (TMS, US, Gordon Research Conference in Physical Metallurgy), focussed EU/UK conferences (Beyond Nickel-Based Superalloys, Nuclear Materials and Intermetallics), UK-specific meetings (UK Nuclear Academics meeting) as well as CDT- and programme-grant specific large workshops.
Societal impact will be maximised through outreach targeting four groups:
1) Ages 12-16, encouraging STEM uptake, at local secondary school visits, via UoB and CCFE, and at science festivals, e.g. New Scientist Live.
2) Ages 16-18, encouraging enrolment in science and engineering degrees, utilising the widening participation programme at UoB on underrepresented groups, and engaged audiences at Pint of Science, Café Scientific and university open days.
3) Public of all ages, will be engaged to promote Science & Engineering and nuclear energy. At festivals, events and talks as mentioned, and the BlueDot festival with CCFE, working with the Henry Royce Institute engagement officer based at UoB, and to seek media engagement via the UoB and CCFE press offices and Science Media Centre.
4) Public policy, will be influenced via the annual UK Nuclear Academics Meetings, BEIS and Parliamentary secondments, UK AMR programme and UK GIF representation.
This research will be disseminated through peer review journal publications and conference presentations and through outreach to UK industry at workshops, IOM3 meetings and company visits. Quarterly meetings with Rolls-Royce and TIMET will ensure the steel/titanium alloys align with engineering and scale up requirements, and the progress of new tungsten alloys discussed with CCFE and EURO-Fusion partners.
Exploitable IP will be patented and licensed jointly with the industrial partners and through University of Birmingham Enterprise. For alloy development IP it is critical to involve industrial partners both at the end application (e.g. Rolls-Royce and CCFE) and primary production (e.g. TIMET). Firstly this is to demonstrate the need, secondly, to ensure that the innovative material can be produced in a practical and cost-competitive manner capable of displacing the existing materials. TIMET and Rolls-Royce have well established routes for the commercialisation of new materials and long-term cooperative agreements with UoB. Onward research grants (e.g. Innovate UK) will also be sought to support this academically, alongside further industry co-funded PhDs, leveraging government funds to deliver impact.
Another impact will be training of new materials engineers, through the promised PhD funding (UoB, CCFE, Rolls-Royce and TIMET) and MSc students. Metallurgists are in great demand from UK job creators (e.g. Firth Rixson, Tata, JLR, BMW-Mini, TIMET, Siemens, EDF, Safran, Hitachi, Airbus, etc, and Rolls-Royce), as well as UK government and infrastructure (rail, BAE systems, MOD, etc). This supply gap has been met by cross-training scientists/engineers from other disciplines and by immigration, which given the UK's recent societal shift there is a need for the UK to internally grow highly qualified engineers.
Throughout the fellowship the research will regularly be disseminated through peer reviewed papers toward high impact journals. The work will also be presented at the major international conferences in the field (TMS, US, Gordon Research Conference in Physical Metallurgy), focussed EU/UK conferences (Beyond Nickel-Based Superalloys, Nuclear Materials and Intermetallics), UK-specific meetings (UK Nuclear Academics meeting) as well as CDT- and programme-grant specific large workshops.
Societal impact will be maximised through outreach targeting four groups:
1) Ages 12-16, encouraging STEM uptake, at local secondary school visits, via UoB and CCFE, and at science festivals, e.g. New Scientist Live.
2) Ages 16-18, encouraging enrolment in science and engineering degrees, utilising the widening participation programme at UoB on underrepresented groups, and engaged audiences at Pint of Science, Café Scientific and university open days.
3) Public of all ages, will be engaged to promote Science & Engineering and nuclear energy. At festivals, events and talks as mentioned, and the BlueDot festival with CCFE, working with the Henry Royce Institute engagement officer based at UoB, and to seek media engagement via the UoB and CCFE press offices and Science Media Centre.
4) Public policy, will be influenced via the annual UK Nuclear Academics Meetings, BEIS and Parliamentary secondments, UK AMR programme and UK GIF representation.
Organisations
- University of Birmingham (Lead Research Organisation)
- Timet UK Ltd (Collaboration)
- Culham Centre for Fusion Energy (Collaboration)
- Rolls Royce Group Plc (Collaboration)
- UNIVERSITY OF MANCHESTER (Collaboration)
- UNIVERSITY OF OXFORD (Collaboration)
- BANGOR UNIVERSITY (Collaboration)
- National Nuclear Laboratory (Collaboration)
- Timet UK Ltd (Project Partner)
- ETH Zurich (Project Partner)
- CCFE/UKAEA (Project Partner)
- ANSTO (Project Partner)
- Max Planck Institutes (Project Partner)
- Rolls-Royce (Project Partner)
People |
ORCID iD |
Alexander Knowles (Principal Investigator / Fellow) |
Publications

D.J.M.King
(2022)
High temperature zirconium alloys for fusion energy
in Journal of Nuclear Materials

Ferreirós P
(2022)
TMS 2022 151st Annual Meeting & Exhibition Supplemental Proceedings

Ferreirós P
(2023)
VNbCrMo refractory high-entropy alloy for nuclear applications
in International Journal of Refractory Metals and Hard Materials

Ferreirós P
(2021)
Effects of thermo-mechanical process on phase transitions, hydrogen solubility and corrosion of Ta-modified Zr-1Nb alloys
in Journal of Nuclear Materials

Ferreirós P
(2022)
Influence of precipitate and grain sizes on the brittle-to-ductile transition in Fe-Al-V bcc-L21 ferritic superalloys
in Materials Science and Engineering: A

Jones R
(2021)
A binary beta titanium superalloy containing ordered-beta TiFe, alpha and omega
in Scripta Materialia

Knowles A
(2021)
Tungsten-based bcc-superalloys
in Applied Materials Today

Ma K
(2023)
Chromium-based bcc-superalloys strengthened by iron supplements
in Acta Materialia

O'Kelly P
(2023)
Ti-Fe Phase Evolution and Equilibria Toward ß-Ti Superalloys
in Journal of Phase Equilibria and Diffusion

Parkes N
(2023)
Tungsten-based bcc-superalloys: Thermal stability and ageing behaviour
in International Journal of Refractory Metals and Hard Materials
Description | Bcc-superalloys are a new class of material that has not yet been commercialised. Here we have made major progress to enable their use, working closely with industry, whilst also achieving top science outputs. |
Exploitation Route | Proof of concept achieved, balanced of properties to be refined to process technology readiness level. |
Sectors | Aerospace Defence and Marine Energy |
Description | Advisory, proof of concept demonstration for 'bcc-superalloys', toward possible application with Rolls Royce (aero jet engines), TIMET (titanium producer), UKAEA and NNL - for fusion and fission reactors. |
First Year Of Impact | 2021 |
Sector | Aerospace, Defence and Marine,Energy |
Impact Types | Economic |
Description | FST FFL Policy Network |
Geographic Reach | National |
Policy Influence Type | Membership of a guideline committee |
Impact | Policy Network & advisory |
URL | https://www.foundation.org.uk/Future-Leaders |
Description | Landscape Report - Materials for Nuclear Enabled Hydrogen |
Geographic Reach | National |
Policy Influence Type | Contribution to a national consultation/review |
Impact | Hydrogen will be a key component toward Net Zero, however, how we produce low/zero-carbon hydrogen remains a challenge to be solved. Nuclear offers signitican potential to produce low/zero-carbon hydrogen and the pathways to this are discussed in the report. |
URL | https://www.royce.ac.uk/content/uploads/2023/12/FINAL-Materials-for-Nuclear-Enabled-Hydrogen-Report.... |
Description | UK Fusion Materials Steering Board |
Geographic Reach | Multiple continents/international |
Policy Influence Type | Contribution to a national consultation/review |
Impact | Advancing progress toward fusion energy |
URL | https://www.royce.ac.uk/content/uploads/2021/09/UK_Fusion_Materials_Roadmap_Interactive.pdf |
Description | COMPASsCO2 |
Amount | € 5,996,892 (EUR) |
Funding ID | 958418 |
Organisation | European Commission H2020 |
Sector | Public |
Country | Belgium |
Start | 11/2020 |
End | 10/2024 |
Description | Irradiation Behaviour of Advanced Nano-Structured Alloys for Fusion Energy, with UKAEA |
Amount | £50,000 (GBP) |
Organisation | UK Atomic Energy Authority |
Sector | Public |
Country | United Kingdom |
Start | 08/2022 |
End | 09/2025 |
Description | PhD studentship in Intermetallic strengthened high temperature steels for demanding fusion plant applications, with UKAEA |
Amount | £50,000 (GBP) |
Organisation | Culham Centre for Fusion Energy |
Sector | Academic/University |
Country | United Kingdom |
Start | 08/2023 |
End | 08/2027 |
Description | PhD studentship in Novel High Entropy Alloys (HEAs) for Advanced Modular Reactors (AMRs), with National Nuclear Laboratory (NNL) |
Amount | £50,000 (GBP) |
Organisation | National Nuclear Laboratory |
Sector | Public |
Country | United Kingdom |
Start | 08/2022 |
End | 09/2025 |
Description | Understanding Novel Tungsten High Entropy Alloys Ductile-Brittle & Irradiation Behaviour for Fusion, with UKAEA STEP |
Amount | £50,000 (GBP) |
Organisation | UK Atomic Energy Authority |
Sector | Public |
Country | United Kingdom |
Start | 08/2022 |
End | 09/2025 |
Description | Bangor University |
Organisation | Bangor University |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Collaborative research grant |
Collaborator Contribution | Collaborative research grant |
Impact | Papers and grants. |
Start Year | 2020 |
Description | NNL |
Organisation | National Nuclear Laboratory |
Country | United Kingdom |
Sector | Public |
PI Contribution | Advisory, quarterly meetings. Research aligned to NNL R&D programme for high temperature fission reactors - Gen-IV / AMRs. |
Collaborator Contribution | Advisory, quarterly meetings. Access to Small Punch testing for mechanical properties. |
Impact | Ongoing |
Start Year | 2020 |
Description | NNL |
Organisation | National Nuclear Laboratory |
Country | United Kingdom |
Sector | Public |
PI Contribution | Advisory, quarterly meetings. Research aligned to NNL R&D programme for high temperature fission reactors - Gen-IV / AMRs. |
Collaborator Contribution | Advisory, quarterly meetings. Access to Small Punch testing for mechanical properties. |
Impact | Ongoing |
Start Year | 2020 |
Description | Rolls-Royce |
Organisation | Rolls Royce Group Plc |
Country | United Kingdom |
Sector | Private |
PI Contribution | Project review meetings with affiliated PhD student |
Collaborator Contribution | Project review meetings with affiliated PhD student |
Impact | Many common papers and support for grants with industrial steer |
Start Year | 2011 |
Description | TIMET |
Organisation | Timet UK Ltd |
Country | United Kingdom |
Sector | Private |
PI Contribution | Co-sponsored PhD student 50:50 TIMET-UoB, review meetings, industrial steer. |
Collaborator Contribution | Co-sponsored PhD student 50:50 TIMET-UoB, review meetings, industrial steer. |
Impact | Co-sponsored PhD student 50:50 TIMET-UoB, review meetings, industrial steer. |
Start Year | 2015 |
Description | UKAEA |
Organisation | Culham Centre for Fusion Energy |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Advisory, quarterly review meetings Research programme aligned to CCFE materials R&D programme. Editor on Fusion Materials Roadmap - https://www.gov.uk/government/news/uk-fusion-materials-roadmap-aims-to-accelerate-progress-in-developing-fusion-power-plants |
Collaborator Contribution | Co-funded CCFE+UoB PhD studentship (additional to start Oct 2022). Experiments, nano-indentation Advisory, quarterly review meetings |
Impact | Editor on Fusion Materials Roadmap - https://www.gov.uk/government/news/uk-fusion-materials-roadmap-aims-to-accelerate-progress-in-developing-fusion-power-plants |
Start Year | 2017 |
Description | University of Manchester |
Organisation | University of Manchester |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Collaborations |
Collaborator Contribution | Collaborations |
Impact | Collaboration, research grants. |
Start Year | 2020 |
Description | University of Oxford |
Organisation | University of Oxford |
Department | Department of Materials |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Interlinked PhD projects with programme. Quarterly meetings. |
Collaborator Contribution | Advisory and linked experimental programmes. Atom Probe Tomography experiments. Onward plans for lithium corrosion testing. |
Impact | Work still underway, joint publications anticipated. |
Start Year | 2021 |
Description | Conference Organiser: BCC Superalloy Network Opening Workshop |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | The BCC Superalloys workshop brought together the growing community of BCC researchers, with topics including, but not limited to: refractory metal bcc-superalloys (e.g. for W), bcc refractory metal high entropy superalloys (RSAs and Naka+Khan type RHEAs), Beta-Ti superalloys, Cr bcc-superalloys, Ferritic superalloys, A2-B2 eutectics / composites. The workshop sparked interest in future events and collaboration. |
Year(s) Of Engagement Activity | 2024 |
URL | https://more.bham.ac.uk/M4X/bcc-snow/ |
Description | FST FFL Policy Network |
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 | Foundation for Science and Technology Foundation Future Leaders 2021 Cohort Alumni network - ~bi-monthly attendence at policy events The programme brings together a cohort of around 30 mid-career professionals over the course of a year, with approximately 10 representatives each from the research community, industry, and the civil service and wider public sector. Over a 12-month period, the group meet and discuss with senior figures from government, parliament, universities, large industry, SMEs, research charities and others. Just as importantly, Future Leaders present their own expertise, develop skills and make future contacts. The programme includes external visits and the development of an annual conference for a wider group of mid-career future leaders in science, technology, research and innovation. |
Year(s) Of Engagement Activity | 2021,2022,2023,2024 |
URL | https://www.foundation.org.uk/Future-Leaders |
Description | Futurum Careers Outreach Article |
Form Of Engagement Activity | A magazine, newsletter or online publication |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Schools |
Results and Impact | Futurum Careers Outreach Article. YOUR ARTICLE FEATURED IN ISSUE 15 OF FUTURUM, PUBLISHED ON 18 JULY 2022 Public engagement stats: 42,697 impressions, 261 engagements, 12 likes, 8 retweets 42,376 people reached, 12,604 engagements, 13 link clicks, 1 like 338 impressions, 7.1 % engagement rate, 3 likes, 3 link clicks, 9 shares 3,124 impressions, 9 pin clicks, 1 save From the Futurum website: 82 PDF downloads |
Year(s) Of Engagement Activity | 2022 |
URL | https://doi.org/10.33424/FUTURUM281 |
Description | Materials for Extremes website |
Form Of Engagement Activity | Engagement focused website, blog or social media channel |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | The group website hosts information about the current research conducted in the group including research interests, capabilities, and achievements. It has also been used a platform to advertise and report on academic workshops. As the website grows, it will reach a broader audience. |
Year(s) Of Engagement Activity | 2020,2021,2022,2023,2024 |
URL | https://more.bham.ac.uk/M4X/ |
Description | Open Access Government Policy Article |
Form Of Engagement Activity | A magazine, newsletter or online publication |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Policymakers/politicians |
Results and Impact | Open Access Government policy article published in magazine and available publicly open access on website promoted on social media channels. |
Year(s) Of Engagement Activity | 2022,2023 |
URL | https://doi.org/10.56367/OAG-037-10488 |