Through Process Modelling for Sustainable Aluminium

Innoval is a UK based company that provides a unique resource of independent expertise to the global aluminium industry (producers and users). The company is a key partner in enabling sustainable, cost effective aluminium alloy production, for use in applications such as automotive, aerospace, and packaging.

Innoval have a particular expertise in developing models to predict the evolution of the structure and properties through the complex process chain that aluminium alloys experience. Models are critical to optimize the processing of aluminium alloys and enable the use of greater recycled content, thus moving towards fully closed loop recycling of aluminium. Innoval have developed a library of models for different parts of the process chain, but these models are not connected. This means it is not possible to predict through process microstructure and performance. The aim of this EngD is to take the existing models and couple them to enable a through process simulation capability. To do this, experimental validation will be required at each step, and additional models may be needed to be developed.

The project will therefore involve a combination of computer based modelling and experimental validation of models using advanced techniques such as electron microscopy. The project will involve spending time at Manchester and at Innoval's UK facilty (Banbury). It will also require international travel.

Through the EngD you will gain an in-depth knowledge of, and exposure to, the aluminium industry. This is a rapidly growing field with increasing opportunities due to the benefits of aluminium in lightweighting. On completing the project, you will have a combination of computer modelling and experimental skills that are in strong demand by employers. Candidates are sought with a background in materials science, engineering, physics, or chemistry.

The EPSRC Centre for Doctoral Training in Advanced Metallic Systems was established to address the metallurgical skills
gap, highlighted in several reports [1-3] as a threat to the competitiveness of UK industry, by training non-materials
graduates from chemistry, physics and engineering in a multidisciplinary environment. Although we will have supplied ~140
highly capable metallurgical scientists and engineers into industry and academia by the end of our existing programme,
there remains a demonstrable need for doctoral-level training to continue and evolve to meet future industry needs. We
therefore propose to train a further 14 UK based PhD and EngD students per cohort as well as 5 Irish students per
cohort through I-Form.

Manufacturing contributes over 10% of UK GVA with the metals sector contributing 12% of this (£10.7BN [4,5]) and
employing ~230,000 people directly and 750,000 indirectly. It is estimated that ~2300 graduates are required annually to
meet present and future growth [5]. A sizeable portion of these graduates will require metallurgical expertise and current
numbers fall far short. From UK-wide HESA data, we estimate there are ~330 home UG/PGT qualifiers in materials and
~35 home doctoral graduates in metallurgy annually, including existing AMSCDT graduates, so it is unsurprising that
industry continues to report difficulties in recruiting staff with the required specialist metallurgical knowledge and
professional competencies.

As well as addressing this shortfall, the CDT will also impact directly on the companies with which it collaborates, on the
wider high value manufacturing sector and on the UK economy as a whole, as follows:

1. Collaborating companies, across a wide range of businesses in the supply chain including SMEs and research
organisations will benefit directly from the CDT through:

- Targeted projects in direct support of their business and its future development and competitiveness.
- Access to the expertise and facilities of the host institutions.
- Involvement in the training of the next generation of potential employees with advanced technical and leadership skills
who can add value to their organisations.

2. The UK High-Value Manufacturing Community will benefit as the CDT will:

- Develop the underpinning science and advanced-level knowledge base required by future high technology areas, where
there is high expectation of gross added value.
- Provide an enhanced route to exploitation, by covering the full spectrum of technology readiness levels.
- Ensure dissemination of knowledge to the sector, through student-led SME consultancy projects, the National Student
Conference in Metallic Materials and industry events.

3. The wider UK economy will benefit as the CDT will:

- Promote materials science and engineering and encourage future generations to enter the field, through outreach
activities developed by the students that will increase public awareness of the discipline and its contribution to modern
life, and highlight its importance to future innovation and technologies.
- Develop and exploit new technologies and products which will help to maintain a competitive UK advanced
manufacturing sector, ensure an internationally competitive and balanced UK economy for future generations and
contribute to technical challenges in key societal issues such as energy and sustainability.

References:
1. Materials UK Structural Materials Report 2009
2. EPSRC Materials International Review 2008
3. EPSRC Materially Better Call 2013
4. The state of engineering, Engineering UK 2017
5. Vision 2030: The UK Metals Industry's New Strategic Approach, Metals Forum