Development of fluid dynamics for spray applied coatings

Tata Steel is a major steel manufacturing company in both Europe and the UK, having a portfolio comprising automotive, engineering and packaging steels (tinplate).

The packaging production volume of 1.2 million tonnes is manufactured across sites in Wales, the Netherlands, and Belgium. Packaging Steel is a highly demanding market with clean, highly formable steel and exceptional surface properties, selling to the major packaging producers of Europe, UK, and the US.

A nano coating of oil is applied to tinplate to prevent scratching during processing at the can maker. If this oil is applied incorrectly it can result in problems during further processing at the customer. In such cases the surface tension of the tinplate is not compatible with lacquer / solvent system and can result in the product being rejected.

The oil is typically applied via an electrostatic oiler whereby an oil mist is created using pressurised air that subsequently passes through an ionisation field to create a finely dispersed mist that is deposited onto the earthed surface of the target.

The project aims to both enhance the electrospray device and the characterisation techniques used to measure the oil film deposited.

Initially the Research Engineer will characterise selected steel packaging products using a range of laboratory techniques i.e. Uv-VIS, FTIR, TGA, Adhesion Testing, Optical Microscopy and Oil Film Weight measurements. The outcomes will identify methods of interest for measuring oil and reveal any specific difficulties in materials handling, measurement, and analyses. Next steps will involve identifying and testing of technologies with the potential to form oil droplets of a uniform size and the characterisation of oil distribution during forming and after application. The ultimate aim being to deliver improved wettability compatible with new lacquer systems.

The CDT will produce 50 graduates with doctoral level knowledge and research skills focussed on the development and manufacture of functional industrial coatings. Key impact areas are:

Knowledge
- The development of new products and processes to address real scientific challenges existing in industry and to transfer this knowledge into partnering companies. The CDT will enable rapid knowledge transfer between academia and industry due to the co-created projects and co-supervision.
- The creation of knowledge sharing network for partner companies created by the environment of the CDT.
- On average 2-3 publications per RE. Publications in high impact factor journals. The scientific scope of the CDT comprises a mixture of interdisciplinary areas and as such a breadth of knowledge can be generated through the CDT. Examples would include Photovoltaic coatings - Journal of Materials Chemistry A (IF 8.867) and Anti-corrosion Coatings - Corrosion Science (IF 5.245), Progress in Organic Coatings (IF 2.903)
- REs will disseminate knowledge at leading conferences e.g. Materials Research Society (MRS), Meetings of the Electrochemical Society, and through trade associations and Institutes representing the coatings sector.
- A bespoke training package on the formulation, function, use, degradation and end of life that will embed the latest research and will be available to industry partners for employees to attend as CPD and for other PGRs demonstrating added value from the CDT environment.

Wealth Creation
- Value added products and processes created through the CDT will generate benefits for Industrial partners and supply chains helping to build a productive nation.
- Employment of graduates into industry will transfer their knowledge and skills into businesses enabling innovation within these companies.
- Swansea University will support potential spin out companies where appropriate through its dedicated EU funded commercialisation project, Agor IP.

Environment and society
- Functionalised surfaces can potentially improve human health through anti-microbial surfaces for health care infrastructure and treatment of water using photocatalytic coatings.
- Functionalised energy generation coatings will contribute towards national strategies regarding clean and secure energy.
- Responsible research and innovation is an overarching theme of the CDT with materials sustainability, ethics, energy and end of life considered throughout the development of new coatings and processes. Thus, REs will be trained to approach all future problems with this mind set.
- Outreach is a critical element of the training programme (for example, a module delivered by the Ri on public engagement) and our REs will have skills that enable the dissemination of their knowledge to wide audiences thus generating interest in science and engineering and the benefits that investments can bring.

People
- Highly employable doctoral gradates with a holistic knowledge of functional coatings manufacture who can make an immediate impact in industry or academia.
- The REs will have transferable skills that are pertinent across multiple sectors.
- The CDT will develop ethically aware engineers with sustainability embed throughout their training
- The promotion of equality, diversity and inclusivity within our cohorts through CDT and University wide initiatives.
- The development of alumni networks to grow new opportunities for our CDT and provide REs with mentors.