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Projects: Projects for Investigator
Reference Number EP/H020047/1
Status Completed
Energy Categories Energy Efficiency(Transport) 90%;
Not Energy Related 10%;
Research Types Basic and strategic applied research 100%
Science and Technology Fields PHYSICAL SCIENCES AND MATHEMATICS (Metallurgy and Materials) 100%
UKERC Cross Cutting Characterisation Not Cross-cutting 100%
Principal Investigator Professor P Prangnell
No email address given
University of Manchester
Award Type Standard
Funding Source EPSRC
Start Date 10 July 2010
End Date 08 July 2016
Duration 72 months
Total Grant Value £5,762,121
Industrial Sectors Manufacturing; Transport Systems and Vehicles
Region North West
Programme Manufacturing: Engineering
Investigators Principal Investigator Professor P Prangnell , Materials, University of Manchester (99.994%)
  Other Investigator Dr M Preuss , Materials, University of Manchester (0.001%)
Dr J Quinta da Fonseca , Materials, University of Manchester (0.001%)
Dr JD Robson , Materials, University of Manchester (0.001%)
Professor P Skeldon , Materials, University of Manchester (0.001%)
Dr X Zhou , Materials, University of Manchester (0.001%)
Professor PS Bate , Materials, University of Manchester (0.001%)
  Industrial Collaborator Project Contact , Alcoa Europe Flat Rolled Products (0.000%)
Project Contact , Novelis Global Technology Centre, USA (0.000%)
Project Contact , Innoval Technology Ltd (0.000%)
Project Contact , Jaguar Land Rover Limited (0.000%)
Project Contact , National Metals Technology Centre (NAMTEC) (0.000%)
Project Contact , Magnesium Elektron Ltd (0.000%)
Project Contact , Airbus UK Ltd (0.000%)
Project Contact , Australian Commonwealth Scientific and Industrial Research Organisation (CSIRO) (0.000%)
Project Contact , Bridgnorth Aluminium Ltd (0.000%)
Project Contact , Keronite International Ltd (0.000%)
Project Contact , Norton Aluminium Ltd (0.000%)
Project Contact , Alcan Engineered Products, Canada (0.000%)
Project Contact , FEI Company Tools for Nanotechnology, USA (0.000%)
Project Contact , Helmholtz Centre for Materials and Coastal Research (HZG), Germany (0.000%)
Project Contact , TWI Technology Centre (0.000%)
Project Contact , Rolls-Royce PLC (0.000%)
Project Contact , Meridian Lightweight Technologies UK Ltd (0.000%)
Web Site
Abstract To avoid global warming and our unsustainable dependence on fossil fuels, the UK's CO2 emissions are recommended to be reduced by 80% from current levels by 2050. Aerospace and automotive manufacturing are critical to the UK economy, with a turnover of 30 billion and employing some 600,000 worker. Applications for light alloys within the transport sector are projected to double in the next decade. However, the properties and cost of current light alloy materials, and the associated manufacturing processes, are already inhibiting progress. Polymer composites are too expensive for body structures in large volume vehicle production and difficult to recycle. First generation, with a high level of recycling, full light alloy aluminium and magnesium vehicles in production are cheaper and give similar weight savings (~ 40%) and life cycle CO2 footprint to low cost composites. Computer-based design tools are also playing an increasing role in industry and allow, as never before, the optimisation of complex component architectures for increased mass efficiency. High performance alloys are still dominant in aeroengine applications and will provide ~ 30% of the structural components of future aircraft designs, where they will have to be increasingly produced in more intricate component shapes and interfaced with composite materials.To achieve further weight reductions, a second generation of higher performance light alloy design solutions are thus required that perform reliably in service, are recyclable, and have more complex product forms - produced with lower cost, energy efficient, manufacturing processes. With design optimisation, and by combining the best attributes of advanced high strength Al and Mg alloys with composites, laminates, and cheaper steel products, it will be possible to produce step change in performance with cost-effective, highly mass efficient, multi-material structures.This roadmap presents many challenges to the materials community, with research urgently required address the science necessary to solve the following critical issues: How do we make more complex shapes in higher performance lower formability materials, while achieving the required internal microstructure, texture, surface finish and, hence, service and cosmetic properties, and with lower energy requirements? How do we join different materials, such as aluminium and magnesium, with composites, laminates, and steel to produce hybrid materials and more mass efficient cost-effective designs? How do we protect such multi-material structures, and their interfaces against corrosion and environmental degradation?Examples of the many scientific challenges that require immediate attention include, how can we: (i) capture the influence of a materials deformation mechanisms, microstructure and texture on formability, thus allowing computer models to be used to rapidly optimise forming for difficult alloys in terms of component shape and energy requirements; (ii) predict and control detrimental interfacial reactions in dissimilar joints; (iii) take advantage of innovative ideas, like using lasers to 'draw on' more formable microstructures in panels, where it is needed; (v) use smart self healing coating technologies to protect new alloys and dissimilar joints in service, (vi) mitigate against the impact of contamination from recycling on growth of oxide barrier coating, etc.A high priority for the Programme isto help fill the skills gap in metallurgical and corrosion science, highlighted in the EPSRC Review of Materials Research (IMR2008), by training the globally competitive, multidisciplinary, and innovative materials engineers needed by UK manufacturing. The impact of the project will be enhanced by a professionally managed, strategic, research Programme and through promoting a high international profile of the research output, as well as by performing an advocacy role for materials engineeringto the general public
Publications (none)
Final Report (none)
Added to Database 05/01/10