Advanced Materials Technology Key Expertise Theme. astutewales.com

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1 Advanced Materials Technology Key Expertise Theme astutewales.com

2 Understanding the Behaviour of Materials. Materials used to manufacture components is a key area for ensuring efficient production and optimum performance of the component in service. Special Technical Expertise The special technical expertise available from the partnership covers several classes of advanced materials, which include sophisticated multi-component metallic alloys, polymeric materials and elastomers, composites, semiconductors and digital materials. Our Academics Have the expertise to interpret macroscopic behaviour of these materials in terms of the underlying structures and phase transformations at the atomic scale. We have advanced techniques available for studying microstructures of materials. These include high resolution electron and optical microscopes, Atomic Force Microscopes (AFM), Energy Dispersive X-ray Analysis and X-ray Photoelectron Spectroscopy (XPS). We also have capabilities for studying bulk degradation mechanisms, such as fatigue, high temperature creep, embrittlement etc. and surface degradation mechanisms such as oxidation, corrosion and susceptibility to Ultra Violet light. These phenomena have a critical effect on component durability. Improved Knowledge & Understanding Address the Industrial RD&I need Improved knowledge and understanding of materials utilised in existing processes and products and of introducing new materials into products and processing existing materials more efficiently. Photo courtesy of Renishaw Plc. The need to introduce new materials into products, to adopt more innovative techniques for processing other advanced materials, and to better understand materials and their behaviour. Did You Know? Opportunities to develop and enhanced materials and components. The emphasis of research into advanced materials is a key element that will be delivered by Swansea and Cardiff Universities, both rated highly in the 2014 Research Excellence Framework (REF) based on their quality of research in the field. Swansea University Swansea University expertise and excellent strengths in Materials Technology will be conducted through the College of Engineering. Companies do need considerable R&D help in integrating these materials which have complex, direction-dependent properties and require a step-change in processing knowledge, which is where Swansea s specialisations can make a significant contribution. Cardiff University Cardiff University research into advanced materials at Cardiff School of Engineering is on understanding and predicting how the internal microstructure of an engineering material influences its response when applied in the field. Cardiff s focus in the area of sustainable design and manufacturing is on the development of sustainable products, and efficient and sustainable manufacturing processes.

3 Specialisms In the area of Advanced Materials Technology, collaboration with local companies has been extensive during ASTUTE ( ). Our focus is only on areas of demand where we can specifically bring established world-leading and internationally excellent expertise. Our specialisms are outlined through this document: Materials Metals and Alloys Polymeric Materials & Elastomers Composite Materials Semiconductors Applications Phase Transformations (Metals Only) - State Change (e.g. Solid/Liquid) - Solid State Precipitation - Solution Treatments - Eutectoid Reactions - Martensitic Reactions High Resolution Microscopy - Optical Microscopy - Electron Microscopy - Energy Dispersive X-ray Analysis - Micro and nano X-ray computed tomography (microct) Property Characterisation - Mechanical Properties - Electrical Properties - Thermal Properties - Magnetic Properties Surface Degradation Mechanisms - Corrosion and Oxidation - UV Resistance Bulk Degradation Mechanisms - High Temperature Creep - Fatigue - Embrittlement Manufacturing Techniques Additive Layer Manufacturing Fabrication of Electronic Devices Thin Film Coatings Equipment Metal Additive Layer Manufacturing Additive Layer manufacturing (ALM) technology is a digitally driven process that uses a high powered laser to fuse fine metallic powders in to 3D objects, direct from 3D CAD data. The metallic powder is distributed evenly across the build plate in layer thicknesses ranging from 20 to 100 microns forming the 2D cross section. The layer of powder is then fused using the laser in a tightly controlled atmosphere. The process is repeated, building up parts of complex geometries, layer by layer. There is also access to a number of plastic 3D Printers. High Resolution Optical Microscopy These microscopes are used particularly during sample preparation for microstructural analysis. Electron Microscopy We have transmission and scanning electron microscopes available. These can be used for resolving microscopic phases present within a range of materials. Energy Dispersive X-ray Analysis Analysis of Chemical Composition. Atomic Force Microscopy 3D imaging of surface topography at the nanoscale. Laser Material Interaction Lasers have been used to study materials as well as part of their processing. Plasma Etching This technique allows material surfaces to be cleaned or prepared for subsequent processing. High Speed Image Capture Capture processes that occur at speeds undetectable with the human eye. The photograph (left) shows one frame from a test in which a water jet was monitored at x frames a second.

4 Fatigue Analysis This assesses the response of materials to repeated and vatiable forces placed upon them. Corrosion Analysis Sophisticated electrochemical analysis equipment and surface potential scanning techniques can measure the corrosion resistance of materials. Mechanical Deformation Instruments are used to assess how the material responds to shape changing forces. We can, therefore, support a diverse range of companies from automotive and aerospace to medical engineering and potentially food industries. Embedding advanced sustainable technologies into Welsh manufacturing. Photo courtesy of Renishaw Plc. Examples of Industrial Collaborations undertaken with the ASTUTE Project ( ) include: (listed alphabetically) Airborne Systems Ltd. Calsonic Kansei Europe Plc. Consort Precision Diamond Co. Ltd. DTR Medical Ltd. Econotherm UK Ltd. Electronic Motion Systems UK Ltd. Prediction of the fatigue failure of lead-free solders in new power electronic components Flamgard Engineering Ltd. Frontier Medical Products Ltd. FSG Tool and Die Ltd. GTS Flexible Materials Ltd. Haydale Limited Heat, Light and Sound Ltd. HI-LEX Cables Ltd. Design optimization of an automotive transmission cable component Just Rollers Plc. Knott Avonride Ltd. Ledwood Mechanical Engineering Metamet Consultants Ltd. Pembrokeshire Sports Boats Schaeffler (UK) Ltd. Tata Steel UK The Royal Mint Wall Colmonoy Ltd. Weartech International Ltd. All information on our industrial collaborations can be found on astutewales.com

5 ASTUTE 2020 Case Study: Advanced Materials Technology A Study into Assessing the Low Cycle Fatigue Behavior of an Aluminium Conical Lighting Column The Aluminum Lighting Company Ltd. aluminium-lighting.com Background ASTUTE was a pleasure to work with, these results will be of great assistance in our future tendering. Barry Williams, Director The Aluminium Lighting Company is developing novel designs for extruded aluminium lighting columns which can provide many benefits over conventional steel columns. The proposed project has undertaken research into the wind induced low cycle fatigue of aluminium columns. Working with company staff, Swansea University has utilised its expertise in computational fluid dynamics to predict stress distributions in the columns that result from wind induced oscillations, and its capabilities in high resolution microscopy to study potential sites of fatigue failure in the aluminium alloy. About the Project Fatigue failure of lighting columns, as a result of wind and traffic induced vibration, has received particular attention in recent years with the increased number of premature lighting failures on exposed sites. Designs involving welds are particularly at risk due to changes in material structure. The Aluminium Lighting Company (ALC) are market leaders in the UK of fully extruded aluminium lighting columns. Eliminating the use of welds within their columns could potentially give superior fatigue performance and extended life of the columns. The present study investigated how to characterise the low cycle fatigue behaviour of the aluminium lighting columns using Finite Element Analysis (FEA) underpinned by low cycle fatigue testing and supported by the microstructural evaluation of the columns. In addition, ASTUTE has assisted the company with the set-up and data analyses of field tests of columns under wind-loading to provide measured stress data for the FEA analysis. Challenges The collaborative work looking at using FEA, fatigue test data and microstructural evaluation has demonstrated the feasibility of this approach for robust structural loading behaviour for ALC s columns. The FEA modelling has identified regions of the column where fatigue could be an issue. However, after metallurgical inspection it was found that the fully extruded columns exhibited a uniform microstructure and along with the FEA this showed that the stresses were well below the fatigue limit threshold. As a result of this work it has been shown that the ALC columns have a high resistance to fatigue cracking over the lifetime of the column. Impact FEA has highlighted that extruded pre-stressed columns show superior fatigue resistance to welded columns. The stresses simulated in the column have demonstrated that the fatigue life of the column will exceed the desired lifetime of the product. This will enable these columns to be placed in the most demanding of environments where safety is the number one consideration. ALC will also now have increased confidence in using this approach in the future. This collaborative research work enabled the company to gain confidence to the column behaviour when subjected to long term wind load and provided further enhancement. The collaboration with ALC was exemplar and ASTUTE is keen to carry further research with the company. ASTUTE Project Manager aluminium-lighting.com

6 Tel: +44 (0) astutewales.com The ASTUTE 2020 (Advanced Sustainable Manufacturing Technologies) operation has been part-funded by the European Regional Development Fund through the Welsh Government and the participating Higher Education Institutions. ASTUTE 2020 is designed to stimulate growth in Wales by applying advanced engineering technologies to manufacturing challenges driving cutting-edge research and innovation, enabling projects with manufacturing companies, to generate sustainable, higher value goods and services and bring them to a global market.