aluminium research for road transport applications geoff scamans innoval technology and brunel...
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Aluminium Research for Road Transport Applications
Geoff ScamansInnoval Technology and Brunel University
Six AIV replica British Leyland Metros were built in 1983. The sheet moncoque body structure was built from AA5251 sheet while the closure panels consisted of standard steel components.
BL Metro AIV
Five AIV replica Bertone Fiat X1/9s were built in 1986 using AA5251 sheet for the monocoque and AA6010 for the closure panels.
Bertone Fiat X1/9 AIV
A build of 40 Mercury Sable AIVs was completed in 1993 using AA6111 sheet for closure panels and AA5754 sheet for the monocoque structure. The structure was not redesigned yet a weight saving of 46% was achieved.
Ford Taurus/Sable AIV
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Range Rover Sport
Range Rover Sport
Current JLR Aluminium Applications
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Curb Weight kg
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Land Rover TD V8
Land Rover TD V6
Petrol
Diesel
Petrol Hybrid
Passenger Vehicle Emissions (ICE) 2012 UK vehicles
EU Aluminium Automotive Sheet Production Growth (kt)
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90020
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body structures (20%)closures (80%)
EU Growth in Aluminium Automotive Sheet Continuous Heat Treatment Capacity (kt)
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Novelis Sierre2
AMAG, Ranshofen
Hydro, Grevenbroich
Constellium, Neuf Brisach
Aleris, Duffel
Novelis, Sierre
Novelis, Nachterstedt
Alcoa Heat Treatment and Finishing: Davenport
NA Growth in Aluminium Automotive Sheet Continuous Heat Treatment Capacity (kt)
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TBC
Alcoa, Knoxville
Novelis, Oswego
Alcoa, Davenport
Alcoa, Danville
Novelis, Kingston
Jaguar F-type
Projected Growth for Extrusion in Key Automotive Applications (kt)
This analysis based on the predicted growth in EU27 vehicle production from 17.2 million in 2012 to 30 million in 2025, the increase of aluminium in vehicles from 140kg/vehicle to 220 kg/vehicle and the progressive increase in extrusions in the mix from 10 to 15%. The estimate for body may be high if sheet intensive vehicle construction predominates
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Crash Chassis Body
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Range Rover Sport Sand Cast Rear Subframe
2005 2008 20092006 2007 2010 2011 2012 2013 2014 2015 2016 20182017
Steel & Al
Light Metals
Steel & Ti
Al & Mg
EPSRC funding in the area of light metals
This chart includes funding in the area of light metals, either current or announced, in April 2013. Grants are grouped into categories. The named investigators and institutions are those for the Principal Investigators on the grant and the figures represent EPSRC’s contribution (80% FEC). Some grants will have a complete light metals focus, others (in particular large grants) will have other metals and materials as aspects of their research.
Key: Doctoral Training
Fellowships
Programme Grants
Centre for Innovative Manufacturing
Strategic Partnership
Responsive Funding
Targeted Funding
Ti
DTC in Advanced Metallic Systems - Sheffield/Manchester - £6,364,458
DTP in Structurally Metallic Systems for Gas Turbine Applications - Cambridge/Swansea/Birmingham - £6,819,398
A Centre for Doctoral Training on the Theory and Simulation of Materials – Imperial - £6,414,829
Step change materials efficiency for steel and aluminium -Allwood – Cambridge –- £1,565,446
Light Alloys Towards Environmentally Sustainable Transport LATEST2 – Thompson - Manchester – £5,762,121
Centre for Innovative Manufacturing: Liquid Metal Engineering Brunel/Oxford/Birmingham –- £5,119,391
Rolls-Royce Strategic Partnership Structural Metallic Systems for Gas Turbines– Birmingham/Cambridge/Swansea/Sheffield – £7,521,798
Hybrid through process modelling IMMPETUS – Sheffield – £4,517,374
Reducing Emissions by Exploiting Field-Induced Martensitic Transformations Dye – Imperial –- £1,151,930
SAMULET4: UFG Ti-6Al-4V for DB/SPF and Hot-Die Forging of Titanium – Rosochowski, Ewing, Ion, Quin Strathclyde - £2,342,379
Towards Affordable, Closed-Loop Recyclable Future Low Carbon Vehicle Structures - TARF-LCVBrunel/Manchester/Imperial/Nottingham/Strathclyde/Exeter/Brookes/Coventry £4,221,482 Al, Mg & PMC
UK Indemand: a National Research Centre for reducing Industrial Energy and Material useAllwood – Cambridge/Bath/Leeds/Trent £6,173,069
Precision guided flexible formingAllwood – Cambridge/Bath/Leeds/Trent £1,707,194
Centre for Innovative Manufacturing in Laser-based Production Heriot-Watt/Cambridge/Cranfield/Liverpool/Manchester–- £5,571,751
Grain refiner for high performance light metal castings Babu Nandela – Brunel £121,144
Al
Energy saving in the Foundry IndustryJolly – Cranfield £116,344
Micro- and nano-patterning of titanium surfacesDalby – Glasgow £340,919
Ti
Industrial Doctorate Centre: Micro- and NanoMaterials and Technologies – Surrey - £6,168,139
Industrial Doctorate Centre in Advanced Forming and Manufacture– Strathclyde- £1,231,298
Cavitation Melt Processing: (UltraMelt)Eskin – Brunel £340,919
Cryogenic Machining Systems (CRYOSIS) Newman – Bath £224,159
Ti
2005 2008 20092006 2007 2010 2011 2012 2013 2014 2015 2016 20182017
Strategic Affordable Manufacturing in the UK through Leading Environmental Technology (SAMULET)
2005 2008 20092006 2007 2010 2011 2012 2013 2014 2015 2016 20182017
Steel & Al
Light Metals
Al & Mg
EPSRC funding for aluminium research
This chart includes funding in the area of light metals, either current or announced, in April 2013. Grants are grouped into categories. The named investigators and institutions are those for the Principal Investigators on the grant and the figures represent EPSRC’s contribution (80% FEC). Some grants will have a complete light metals focus, others (in particular large grants) will have other metals and materials as aspects of their research.
Key: Fellowships
Programme Grants
Centre for Innovative Manufacturing
Responsive Funding
Step change materials efficiency for steel and aluminium
-Allwood – Cambridge –- £1,565,446
Light Alloys Towards Environmentally Sustainable Transport LATEST2
– Thompson - Manchester – £5,762,121
Centre for Innovative Manufacturing: Liquid Metal Engineering
Brunel/Oxford/Birmingham –- £5,119,391
Hybrid through process modelling IMMPETUS – Sheffield – £4,517,374
Towards Affordable, Closed-Loop Recyclable Future Low Carbon Vehicle Structures - TARF-LCV
Brunel/Manchester/Imperial/Nottingham/Strathclyde/Exeter/Brookes/Coventry £4,221,482
Al, Mg & PMCs
UK Indemand: a National Research Centre for reducing Industrial Energy and Material use
Allwood – Cambridge/Bath/Leeds/Trent £6,173,069
Precision guided flexible formingAllwood – Cambridge/Bath/Leeds/Trent £1,707,194
Centre for Innovative Manufacturing in Laser-based Production
Heriot-Watt/Cambridge/Cranfield/Liverpool/Manchester–- £5,571,751
Grain refiner for high performance light metal castings Babu Nandela – Brunel £121,144 Al
Energy saving in the Foundry IndustryJolly – Cranfield £116,344
Cavitation Melt Processing: (UltraMelt)Eskin – Brunel £340,919
2005 2008 20092006 2007 2010 2011 2012 2013 2014 2015 2016 20182017
Towards Affordable, Closed-Loop Recyclable Future Low Carbon Vehicle Structures:Metallic Materials Group Objectives
BCAST, Brunel University
Geoff Scamans
Research Vision and Ambition
Vehiclemanufacturing Vehicle use ELVs Primary
input materialsRecovered metals
(down graded)
Wastefor land filling
CO2 emission2011
2030Low-carbon input
lightweightmaterials
Low-carbonmanufacturingtechnologies Mass-optimised
design forlow-carbon usage
ELVs (end of life vehicles)
Dismantling ofELVs
Reuse &remanufacture
Closed-looprecycling
Limited input ofprimary materials
Significantlyreduced CO2
Minimal wastefor land filling
Project Objectives
To develop closed-loop recyclable Al-alloys and self-corrosion-resistant Mg-alloysTo develop advanced PMCs using recyclable rGFs, rCFs and recoverable rNFsTo develop novel technologies for liquid metal treatment to enable closed-loop recyclingTo develop advanced technologies for LC manufacturing and effective disassembly of ELVsTo develop mass-optimised vehicle design principlesTo develop specific LCA methodology for future LCV development
Recyclable Aluminium BIW
• Magnesium content is not an issue• AlSi casting alloys result in a high silicon level in
the remelted BIW alloy• AlMg casting alloys are a promising alternative
(RASCAL TSB project)• Tolerance of iron is important for casting, sheet
and extrusion alloys (RecycAL FP7 project)• Recycled alloys should be used for both the
closure panel and structure
Development of the rheo-diecasting process for lightweight automotive components (RDC)Innoval, Brunel University, Ford Jaguar, JVM Castings, Meridian, NAMTEC £1,673,893
Direct Chill RheoCasting of High Performance Aluminium Alloys (DCRC) Innoval, Alcan, Novelis, Brunel, Luxfer Gas Cylinders, Zyomax £2,012,562
Structural Adhesive Bonding of thick Components for Advanced Design (SABCAD)Airbus, BAE Systems, Imperial, Surrey £693,255
Upcycling of Light Alloys by Rheoforming Scrap (ULARS) Innoval, Meridian, Norton Aluminium, Zyomax and Brunel £1,614,996
Recyclable Ultra Light Mixed material Automotive Platform (RULMAP) Innoval, IQuad, Atlas Composites, Boal and Oxford £768,317
Lower Cost, Light Weight Vehicles by Increasing the Use of Post Consumer Aluminium Scrap (REALCAR) JLR, Novelis, Norton Aluminium, Zyomax, Innoval, Brunel £1,908,711
Limo GreenJaguar, Caparo, Lotus, MIRA £4,104,789
CAE reliability tools and design methods for structures with hybrid bonded joints (BONDEDCAR) JLR, Coventry, nCode, Stoke Golding, Novelis, Dow, Innoval, and Henrob £1,218,135
Replacement of Copper by Aluminium in Electrical Heating Cables (HEATAL) Heat Trace, Innoval, 3M, Whatlow and Manchester £2,356,354
Warm Aluminium Forming Technology (WAFT) JLR, Dutton, Innoval, Novelis, Stadco, Whiston, Fuchs and Imperial £2,842,974
Plastic Net-Forming of Metal (PLANET) Innoval, JLR, Corus, Plastic Omnium, Sabic and Warwick £496,098
Key 2004 - 2010:
Advanced Materials
Environmental Sustainability
High Value Manufacturing
TSB funding in the area of light metals (aluminium and magnesium)
This chart includes collaborative R&D projects with a significant light metal content that have been funded from competitions from 2004 to 2013. The figures represent the total value of the project. TSB typically provides 50% of the funding support inline with state aid rules.
Grain refiner for lightweight aluminium automotive castings Innoval, Grainger & Worrall, ESI-Group, LSM and JLR £705,418
Recyclable aluminium structural casting alloy (RASCAL)JLR, Innoval, JVM, Norton, Brunel University £885,099
Recycled tolerant aluminium alloy utilising post consumer waste (REALCAR2)
JLR, Innoval, Novelis, Aleris and Warwick University £980,708
Novel Aluminium Dross/Salt Slag Press Technology
Altek £626,622
High quality surface finished aluminium rollers for mass replication (REPLICAL)
Innoval, Macdermid, Stockfield £413,970
Magnesium Intensive BIW Structures for the Premium Automotive Sector
Morgan, Penso, MEL, Coventry University, Luxfer £1,415,154
Hi-TINAL: Advanced High-Tin Aluminium Plain Bearing Alloys
Rolls Royce, Brunel, KC Engineering £542,682
Aluminium Matrix Composite Materials for vehicle Weight Reduction
JLR, Composite Metal Technolgy, Antich £2,115,281
Innovative Microstructural Design for Advanced Al Alloys (IDEAL)Rolls-Royce, Aeromet, University of Birmingham £569,453
On-line control of Friction Stir Welding processes using ultrasonic testingThompson Friction, TWI, Theta, GKN £870,696
Light weight 7.5 - 12 tonne Future Truck Chassis Concept
Leyland Trucks, Sapa, MI Technology £1,252,530
Aluminium Lattice Structures via Additive Manufacturing
Econolyst, Alcon, Axon, Delcam, Delphi, Loughborough U, NottinghamU, Renishaw £1,066,769
Resource Efficiency
Technology Inspired Innovation
Manufacturing
Low Carbon Vehicles
Key 2010 - 2015:
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
A20X High Value Large Structure Casting
Aeromet, LSM, JLR, JVM, University of Birmingham £830,300
HITEA: REACH Compliant Hexavalent Chrome Replacement Rolls Royce, GE, BAe Systems, Goodrich, Aeroengine Controls £2,200,000
Highly Innovative Technology Enablers In Aerospace
Ultra-light Car Bodies (UlCab) PAB, Impression Technologies, Lotus,Innoval, Imperial College £1,117,026
TSB active projects (aluminium)
This chart includes collaborative R&D projects with a aluminium and automotive content that have been funded from competitions from 2010 to 2014. The figures represent the total value of the project. TSB typically provides 50% of the funding support inline with state aid rules.
Grain refiner for lightweight aluminium automotive castings
Innoval, Grainger & Worrall,ESI-Group, AMG and JLR
£705,418
Recyclable aluminium structural casting alloy (RASCAL)
JLR, Innoval, JVM, Norton, Brunel University
£885,099
Recycled tolerant aluminium alloy utilising post consumer waste (REALCAR2)
JLR, Innoval, Novelis, Aleris and Warwick University £980,708
Hi-TINAL: Advanced High-Tin Aluminium Plain Bearing Alloys
Rolls Royce, Brunel, KC Engineering £542,682
Aluminium Matrix Composite Materials for vehicle Weight Reduction
JLR, Composite Metal Technology, Antich £2,115,281
On-line control of Friction Stir Welding processes using ultrasonic testing
Thompson Friction, TWI, Theta, GKN £870,696
Light weight 7.5 - 12 tonne Future Truck Chassis Concept
Leyland Trucks, Sapa, MI Technology £1,252,530
Aluminium Lattice Structures via Additive Manufacturing
Econolyst, Alcon, Axon, Delcam, Delphi, Loughborough U, NottinghamU, Renishaw
£1,066,769
Resource Efficiency
Technology Inspired Innovation
Manufacturing
Low Carbon Vehicles
2010 2011 2012 2013 2014 2015
2010 2011 2012 2013 2014 2015
A20X High Value Large Structure Casting Aeromet, LSM, JLR, JVM, U of Birmingham
£830,300
Ultra-light Car Bodies (UlCab) PAB, Impression Technologies, Lotus,
Innoval, Imperial College £1,117,026
REALCAR 2
Aluminium RSIs
Mechanical Biological
Treatment (MBT)
Aluminium from MBT EMR Shredder EMR Media
Separation
Aluminium Melting
DC castingCoil rolling
Consortium Partners
Advanced Light Metals Processing Research Centre
•Brunel University has been granted £3.9M from the Engineering and Physical Sciences Research Council (EPSRC) for the creation of a national scale-up facility for automotive light metals research initially in collaboration with Jaguar Land Rover and Constellium. Brunel University will supplement this grant with a further £5.5M for a dedicated building and support resource at their site in Uxbridge
•The goal of the “Advanced Light Metals Processing Research Centre” will be to bridge the gap between fundamental research and industrial applications, allowing rapid exploitation of innovations developed at the laboratory scale
•The Centre aims to provide high-performance light alloys, resource-efficient casting technologies, extrusion processing technologies and component innovations to meet the mid- and long-term needs of the automotive industry
•Of strategic importance will be a fully integrated DC casting and extrusion facility, which is planned to include a full-size 1600 ton extrusion press complete with support facilities and full automation, and commercial scale high pressure and low pressure die casting machines
Operational Q3 2014: 1300m2 approx
Advanced Light Metals Processing Research Centre
Summary
EPSRC support for aluminium and magnesium is concentrated within LiME, LATEST2, TARF-LCV. These programmes support a large number of RAs and PhDs
The Advanced Metallics DTC supports a small number of aluminium PhD projects
The support for aluminium research is broadly similar to that of titanium but much lower than the support for PMCs
TSB funding to date has supported about 20 aluminium projects to date with a total project value of over £50m
Most of the support is for automotive and aerospace related applications