Development of new innovative materials and CNC processing routes

Machinability of Ni-based super alloys is a constantly evolving topic, driven by the development of improved alloys for the aerospace industry. New alloys with improved strength and that are designed for higher working temperatures are created through changes in processing methods and alloying conditions, and thereby microstructure. In parallel, new near net shape and additive manufacturing processing methods are being deployed. This project aims to understand the impact of these changes on the performance and wear mechanisms of Sandvik cutting tools, as a basis for development of the next generation of tools. The cutting conditions, deformation behaviour and chemical reactions during cutting of these materials are new, and therefore need to be developed in combination with machining developments.

Whilst machinability of Ni-base superalloys is a topic that has been widely examined in academic circles, it has generally been focussed on Inconel 718 that has been produced through conventional processing routes. As new alloys have come into mainstream use, and as processing methods have changed towards near net and additive manufacture, manufacturers need to understand the implications of these changes. New processing routes or fundamental changes in materials machinability and in-service performance may necessitate manufacturers to change the way they develop and use cutting tools.

Sandvik Coromant is the world leader in cutting tools to the aerospace manufacturing industry. To maintain their position they invest in Research and Development programmes to build their own knowledge base and ensure they remain ahead in understanding their customer's latest processes and materials requirements.

This project is supervised by Professor Martin Jackson in the Department of Materials Science and Enginnering at the University of Sheffield, and by Dr Pete Crawforth at the Advanced Manufacturing Research Centre (AMRC) in Sheffield. The student will also work closely with Sandvik Coromant in machining Ni-based superalloys, with additional support from Sandvik Coromant R&D resources in Sheffield and Sweden. The student will also benefit from Coromants knowledge of the performance and application of cutting tools and turning, and have access to prototype tools to facilitate testing of scientific principles. It is expected that the student will therefore spend time at the Univerity of Sheffield and the AMRC, and also with Sandvik in Sheffield and Sweden as required, in delivering the project.

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