MAPP: EPSRC Future Manufacturing Hub in Manufacture using Advanced Powder Processes

Completed

Not Energy Related
Energy Efficiency(Industry)

Basic and strategic applied research

PHYSICAL SCIENCES AND MATHEMATICS (Metallurgy and Materials)
ENGINEERING AND TECHNOLOGY (Mechanical, Aeronautical and Manufacturing Engineering)

Not Cross-cutting

Professor I Todd
Engineering Materials
University of Sheffield

Standard

EPSRC

01 October 2016

30 June 2024

93 months

£10,724,131

Manufacturing

Yorkshire & Humberside

Manufacturing : Manufacturing

Professor I Todd, Engineering Materials, University of Sheffield

Professor A Bayly, Chemical and Process Engineerin, University of Leeds
Dr F Giuliani, Department of Mechanical Engineering, Imperial College London
Professor P Grant, Materials, University of Oxford
Dr A Hassanpour, Chemical and Process Engineerin, University of Leeds
Dr J Hughes, Advanced Manufacturing Res Centre Boeing, University of Sheffield
Dr M Jackson, Engineering Materials, University of Sheffield
Professor V Kadirkamanathan, Automatic Control and Systems Engineering, University of Sheffield
Professor PD Lee, Materials, University of Manchester
Dr CE Majewski, Mechanical Engineering, University of Sheffield
Professor AM Mullis, Chemical and Process Engineerin, University of Leeds
Dr K Mumtaz, Mechanical Engineering, University of Sheffield
Dr G Panoutsos, Automatic Control and Systems Engineering, University of Sheffield
Professor P Prangnell, Materials, University of Manchester
Dr M Preuss, Materials, University of Manchester
Professor WM Rainforth, Engineering Materials, University of Sheffield
Professor E Saiz Gutierrez, Materials, Imperial College London
Dr LJM Vandeperre, Materials, Imperial College London
Professor P Withers, Materials, University of Manchester

Project Contact, Freeman Technology
Project Contact, Rolls-Royce PLC
Project Contact, Johnson Matthey Plc
Project Contact, Metalysis Limited
Project Contact, The Weir Group plc
Project Contact, Centre for Process Innovation - CPI
Project Contact, Morgan Advanced Materials and Technology
Project Contact, University of Strathclyde
Project Contact, National Composites Centre
Project Contact, Phoenix Scientific Industries Limited
Project Contact, Nuclear AMRC
Project Contact, MAHER Limited
Project Contact, Eastman Chemical Company, USA
Project Contact, Seco Tools
Project Contact, LPW Technology Ltd (UK)
Project Contact, Carl Zeiss Limited
Project Contact, Messier-Dowty Ltd
Project Contact, Element Six Ltd (UK)
Project Contact, The Manufacturing Technology Centre Ltd
Project Contact, University of Chichester
Project Contact, Bexhill College
Project Contact, Xaar Plc
Project Contact, Renishaw PLC (Old Town)
Project Contact, GKN Aerospace
Project Contact, University of Nottingham
Project Contact, University of Sheffield
Project Contact, University of Warwick

Manufacture Using Advanced Powder Processes - MAPPConventional materials shaping and processing are hugely wasteful and energy intensive. Even with well-structured materials circulation strategies in place to recondition and recycle process scrap, the energy use, CO2 emitted and financial costs associated are ever more prohibitive and unacceptable. We can no longer accept the traditional paradigm of manufacturing where excess energy use and high levels of recycling / down cycling of expensive and resource intensive materials are viewed as inevitable and the norm and must move to a situation where 100% of the starting material is incorporated into engineering products with high confidence in the final critical properties.MAPP's vision is to deliver on the promise of powder-based manufacturing processes to provide low energy, low cost, and low waste high value manufacturing route and products to secure UK manufacturing productivity and growth. MAPP will deliver on the promise of advanced powder processing technologies through creation of new, connected, intelligent, cyber-physical manufacturing environments to achieve 'right first time' product manufacture. Achieving our vision and realising the potential of these technologies will enable us to meet our societal goals of reducing energy consumption, materials use, and CO2 emissions, and our economic goals of increasing productivity, rebalancing the UK's economy, and driving economic growth and wealth creation.We have developed a clear strategy with a collaborative and interdisciplinary research and innovation programme that focuses our collective efforts to deliver new understanding, actions and outcomes across the following themes:1) Particulate science and innovation. Powders will become active and designed rather than passive elements in their processing. Control of surface state, surface chemistry, structure, bulk chemistry, morphologies and size will result in particles designed for process efficiency / reliability and product performance. Surface control will enable us to protect particles out of process and activate them within. Understanding the influence between particle attributes and processing will widen the limited palette of materials for both current and future manufacturing platforms.2) Integrated process monitoring, modelling and control technologies. New approaches to powder processing will allow us to handle the inherent variability of particulates and their stochastic behaviours. Insights from advanced in-situ characterisation will enable the development of new monitoring technologies that assure quality, and coupled to modelling approaches allow optimisation and control. Data streaming and processing for adaptive and predictive real-time control will be integral in future manufacturing platforms increasing productivity and confidence.3) Sustainable and future manufacturing technologies. Our approach will deliver certainty and integrity with final products at net or near net shape with reduced scrap, lower energy use, and lower CO2 emissions. Recoupling the materials science with the manufacturing science will allow us to realise the potential of current technologies and develop new home-grown manufacturing processes, to secure the prosperity of UK industry.MAPP's focused and collaborative research agenda covers emerging powder based manufacturing technologies: spark plasma sintering (SPS), freeze casting, inkjet printing, layer-by-layer manufacture, hot isostatic pressing (HIP), and laser, electron beam, and indirect additive manufacturing (AM). MAPP covers a wide range of engineering materials where powder processing has the clear potential to drive disruptive growth - including advanced ceramics, polymers, metals, with our initial applications in aerospace and energy sectors - but where common problems must be addressed.

04/01/19