Advanced Metals Processing

The Advanced Metals Processing Research Area aims to build on the UK’s strength in metals processing and provide the support needed to deliver innovative metals processing technologies and novel alloy solutions. It will support the UK metal industries in transitioning to a resource efficient, zero-pollution, digitalized and agile future.

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Introduction and Scope

Metallurgy and metals processing is changing, driven by the need to rapidly transition to a low-carbon and more circular economy. Improved innovation and in-service performance is required, whilst addressing the socio-economic drivers of reducing process waste, and emissions, and development cycle times.

Our focus on metals process innovation is the “missing gap” between small-scale laboratory metals processing and the industrial scale. Through a combination of small-scale experiments, materials characterisation, and modelling, our aim is to develop an integrated computational materials engineering approach to metals processing across the whole manufacturing process, accelerating manufacturing agility and efficiency.

Led by the University of Sheffield and working with the Universities of Manchester and Strathclyde, the Advanced Metals Processing Research Area engages the entire Advanced Metals community in the UK.

Application areas include:

Light weight system solutions for transport industry;
New steels for nuclear industry;
Net shape aerospace components;
Additive repair of high value components;
Materials tailored for orthopaedic applications;
Primary metal suppliers for automotive manufacturers;
Primary metal suppliers for aerospace component manufacturers, gas turbine suppliers.

Current and Future Research

To facilitate and support the development of competitive, resource-efficient, zero-carbon, digitalised, and agile UK metals manufacturing, through:

the adoption of new technologies based around heat from electricity/hydrogen
Materials 4.0 (e.g. “digital twin”) development for rapid and intelligent
process support
new solutions for de-commissioning and recycling/re-use of metal products
(including understanding the resiliance of alloys to repetitive recycling)
the transition to more efficient and affordable processing routes with more
consistent properties to reduce design conservatism (use of less material
by challenging our approach to risk assurance).

Links

Our unique capability has been strategically designed to “stress-test” metals processing and alloy innovations (TRLs 1-2) at an intermediate size scale, and will then move to the industrial scale through the High Value Manufacturing Catapult (HVMC) network, Materials Processing Institute (MPI) and TWI.

Technology Platforms

Royce Technology Platforms are groupings of cutting-edge facilities and expertise. Each Platform has a Technology Platform Lead responsible for developing and enhancing the facilities and supporting related research activities which utilise Royce Equipment

Materials Discovery and Prototyping

Alloy development is where traditional industries and researchers alike look to new materials to meet the challenges posed in the transition to zero carbon, sustainable manufacture, and fostering a circular economy.

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Near Net Shape Manufacturing

This platform offers more efficient material usage, and can significantly reduce machining requirements to better meet national challenges in sustainability, recycling, and the circular economy. These processes can offer greater flexibility, previously inaccessible structures, and reduced costs for the next generation of complex components.

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Thermomechanical Processing

Combining advanced capabilities in forging and hot rolling with cold rolling and sheet metal processing, enabling the development of the next generation of high-value added wrought metal products and processes.

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High Integrity Forging

Together with Royce, the AFRC offers forging and forming houses opportunities to access the latest facilities and ground-breaking capabilities to explore sustainable manufacturing methods and reduce costs.

Coming Soon