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Aluminium Research for Road Transport Applications
Aluminium Research for Road Transport Applications
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Range Rover Sport
Range Rover Sport
Range Rover Sport
Range Rover Sport
Current JLR Aluminium Applications
Current JLR Aluminium Applications
Passenger Vehicle Emissions (ICE) 2012 UK vehicles
Passenger Vehicle Emissions (ICE) 2012 UK vehicles
EU Aluminium Automotive Sheet Production Growth (kt)
EU Aluminium Automotive Sheet Production Growth (kt)
EU Growth in Aluminium Automotive Sheet Continuous Heat Treatment
EU Growth in Aluminium Automotive Sheet Continuous Heat Treatment
Alcoa Heat Treatment and Finishing: Davenport
Alcoa Heat Treatment and Finishing: Davenport
NA Growth in Aluminium Automotive Sheet Continuous Heat Treatment
NA Growth in Aluminium Automotive Sheet Continuous Heat Treatment
Jaguar F-type
Jaguar F-type
Projected Growth for Extrusion in Key Automotive Applications (kt)
Projected Growth for Extrusion in Key Automotive Applications (kt)
Range Rover Sport Sand Cast Rear Subframe
Range Rover Sport Sand Cast Rear Subframe
EPSRC funding in the area of light metals This chart includes funding
EPSRC funding in the area of light metals This chart includes funding
EPSRC funding for aluminium research This chart includes funding in
EPSRC funding for aluminium research This chart includes funding in
Towards Affordable, Closed-Loop Recyclable Future Low Carbon Vehicle
Towards Affordable, Closed-Loop Recyclable Future Low Carbon Vehicle
Research Vision and Ambition
Research Vision and Ambition
Project Objectives
Project Objectives
Aluminium Alloy Development
Aluminium Alloy Development
Recyclable Aluminium BIW
Recyclable Aluminium BIW
TSB funding in the area of light metals (aluminium and magnesium) This
TSB funding in the area of light metals (aluminium and magnesium) This
TSB active projects (aluminium) This chart includes collaborative R&D
TSB active projects (aluminium) This chart includes collaborative R&D
REALCAR 2
REALCAR 2
Advanced Light Metals Processing Research Centre
Advanced Light Metals Processing Research Centre
Advanced Light Metals Processing Research Centre
Advanced Light Metals Processing Research Centre
Summary
Summary

Презентация: «Aluminium Research for Road Transport Applications». Автор: Sophie Oldham (EPSRC,RB). Файл: «Aluminium Research for Road Transport Applications.ppt». Размер zip-архива: 3339 КБ.

Aluminium Research for Road Transport Applications

содержание презентации «Aluminium Research for Road Transport Applications.ppt»
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1 Aluminium Research for Road Transport Applications

Aluminium Research for Road Transport Applications

Geoff Scamans Innoval Technology and Brunel University

2 Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993

Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993

BL Metro AIV

Bertone Fiat X1/9 AIV

Ford Taurus/Sable AIV

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.

Five AIV replica Bertone Fiat X1/9s were built in 1986 using AA5251 sheet for the monocoque and AA6010 for the closure panels.

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.

3 Range Rover Sport

Range Rover Sport

4 Range Rover Sport

Range Rover Sport

5 Current JLR Aluminium Applications

Current JLR Aluminium Applications

6 Passenger Vehicle Emissions (ICE) 2012 UK vehicles

Passenger Vehicle Emissions (ICE) 2012 UK vehicles

7 EU Aluminium Automotive Sheet Production Growth (kt)

EU Aluminium Automotive Sheet Production Growth (kt)

body structures (20%) closures (80%)

8 EU Growth in Aluminium Automotive Sheet Continuous Heat Treatment

EU Growth in Aluminium Automotive Sheet Continuous Heat Treatment

Capacity (kt)

9 Alcoa Heat Treatment and Finishing: Davenport

Alcoa Heat Treatment and Finishing: Davenport

10 NA Growth in Aluminium Automotive Sheet Continuous Heat Treatment

NA Growth in Aluminium Automotive Sheet Continuous Heat Treatment

Capacity (kt)

11 Jaguar F-type

Jaguar F-type

12 Projected Growth for Extrusion in Key Automotive Applications (kt)

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

13 Range Rover Sport Sand Cast Rear Subframe

Range Rover Sport Sand Cast Rear Subframe

14 EPSRC funding in the area of light metals This chart includes funding

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.

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

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

Doctoral Training

A Centre for Doctoral Training on the Theory and Simulation of Materials – Imperial - ?6,414,829

Fellowships

Industrial Doctorate Centre: Micro- and NanoMaterials and Technologies – Surrey - ?6,168,139

Programme Grants

Industrial Doctorate Centre in Advanced Forming and Manufacture– Strathclyde- ?1,231,298

Centre for Innovative Manufacturing

Step change materials efficiency for steel and aluminium -Allwood – Cambridge –- ?1,565,446

Steel & Al

Strategic Partnership

Reducing Emissions by Exploiting Field-Induced Martensitic Transformations Dye – Imperial –- ?1,151,930

Steel & Ti

Responsive Funding

Light Alloys Towards Environmentally Sustainable Transport LATEST2 – Thompson - Manchester – ?5,762,121

Light Metals

Targeted Funding

Centre for Innovative Manufacturing: Liquid Metal Engineering Brunel/Oxford/Birmingham –- ?5,119,391

Al & Mg

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

SAMULET4: UFG Ti-6Al-4V for DB/SPF and Hot-Die Forging of Titanium – Rosochowski, Ewing, Ion, Quin Strathclyde - ?2,342,379

Ti

Micro- and nano-patterning of titanium surfaces Dalby – Glasgow ?340,919

Ti

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 & PMC

Cryogenic Machining Systems (CRYOSIS) Newman – Bath ?224,159

Ti

Grain refiner for high performance light metal castings Babu Nandela – Brunel ?121,144

Al

Energy saving in the Foundry Industry Jolly – Cranfield ?116,344

Cavitation Melt Processing: (UltraMelt) Eskin – Brunel ?340,919

Precision guided flexible forming Allwood – Cambridge/Bath/Leeds/Trent ?1,707,194

UK Indemand: a National Research Centre for reducing Industrial Energy and Material use Allwood – Cambridge/Bath/Leeds/Trent ?6,173,069

Centre for Innovative Manufacturing in Laser-based Production Heriot-Watt/Cambridge/Cranfield/Liverpool/Manchester–- ?5,571,751

Key:

Strategic Affordable Manufacturing in the UK through Leading Environmental Technology (SAMULET)

15 EPSRC funding for aluminium research This chart includes funding in

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.

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

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

Precision guided flexible forming Allwood – Cambridge/Bath/Leeds/Trent ?1,707,194

UK Indemand: a National Research Centre for reducing Industrial Energy and Material use Allwood – Cambridge/Bath/Leeds/Trent ?6,173,069

Centre for Innovative Manufacturing in Laser-based Production Heriot-Watt/Cambridge/Cranfield/Liverpool/Manchester–- ?5,571,751

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

Grain refiner for high performance light metal castings Babu Nandela – Brunel ?121,144

Energy saving in the Foundry Industry Jolly – Cranfield ?116,344

Cavitation Melt Processing: (UltraMelt) Eskin – Brunel ?340,919

Steel & Al

Fellowships

Light Metals

Programme Grants

Centre for Innovative Manufacturing

Al & Mg

Responsive Funding

Al, Mg & PMCs

Al

Key:

16 Towards Affordable, Closed-Loop Recyclable Future Low Carbon Vehicle

Towards Affordable, Closed-Loop Recyclable Future Low Carbon Vehicle

Structures: Metallic Materials Group Objectives

BCAST, Brunel University

Geoff Scamans

17 Research Vision and Ambition

Research Vision and Ambition

2011

2030

18 Project Objectives

Project Objectives

To develop closed-loop recyclable Al-alloys and self-corrosion-resistant Mg-alloys To develop advanced PMCs using recyclable rGFs, rCFs and recoverable rNFs To develop novel technologies for liquid metal treatment to enable closed-loop recycling To develop advanced technologies for LC manufacturing and effective disassembly of ELVs To develop mass-optimised vehicle design principles To develop specific LCA methodology for future LCV development

19 Aluminium Alloy Development

Aluminium Alloy Development

The future LCV body structure will consist of wrought Al sheet and profiles and cast Al shaped components. At the end of vehicle life, the Al parts can be easily removed from the ELVs for direct recycling with little requirement for compositional adjustment. Stronger more crash resistant alloys are required for light weight chassis components (extrusions, forgings and castings) In addition, the powertrain system should consist of components made from one specially designed cast Al-alloy. TARF-LCV aims to develop such Al-alloys, for body sheet, for cast body parts and for powertrain components.

20 Recyclable Aluminium BIW

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

21 TSB funding in the area of light metals (aluminium and magnesium) This

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.

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

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

Manufacturing

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

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

Aluminium Matrix Composite Materials for vehicle Weight Reduction JLR, Composite Metal Technolgy, Antich ?2,115,281

A20X High Value Large Structure Casting Aeromet, LSM, JLR, JVM, University of Birmingham ?830,300

Hi-TINAL: Advanced High-Tin Aluminium Plain Bearing Alloys Rolls Royce, Brunel, KC Engineering ?542,682

Magnesium Intensive BIW Structures for the Premium Automotive Sector Morgan, Penso, MEL, Coventry University, Luxfer ?1,415,154

Light weight 7.5 - 12 tonne Future Truck Chassis Concept Leyland Trucks, Sapa, MI Technology ?1,252,530

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

Grain refiner for lightweight aluminium automotive castings Innoval, Grainger & Worrall, ESI-Group, LSM and JLR ?705,418

Aluminium Lattice Structures via Additive Manufacturing Econolyst, Alcon, Axon, Delcam, Delphi, Loughborough U, NottinghamU, Renishaw ?1,066,769

Recycled tolerant aluminium alloy utilising post consumer waste (REALCAR2) JLR, Innoval, Novelis, Aleris and Warwick University ?980,708

Development of the rheo-diecasting process for lightweight automotive components (RDC) Innoval, Brunel University, Ford Jaguar, JVM Castings, Meridian, NAMTEC ?1,673,893

Key 2004 - 2010:

Advanced Materials

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

High Value Manufacturing

Environmental Sustainability

Key 2010 - 2015:

Technology Inspired Innovation

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 Green Jaguar, Caparo, Lotus, MIRA ?4,104,789

Resource Efficiency

Replacement of Copper by Aluminium in Electrical Heating Cables (HEATAL) Heat Trace, Innoval, 3M, Whatlow and Manchester ?2,356,354

Low Carbon Vehicles

Highly Innovative Technology Enablers In Aerospace

Innovative Microstructural Design for Advanced Al Alloys (IDEAL) Rolls-Royce, Aeromet, University of Birmingham ?569,453

Recyclable aluminium structural casting alloy (RASCAL) JLR, Innoval, JVM, Norton, Brunel University ?885,099

On-line control of Friction Stir Welding processes using ultrasonic testing Thompson Friction, TWI, Theta, GKN ?870,696

HITEA: REACH Compliant Hexavalent Chrome Replacement Rolls Royce, GE, BAe Systems, Goodrich, Aeroengine Controls ?2,200,000

Ultra-light Car Bodies (UlCab) PAB, Impression Technologies, Lotus,Innoval, Imperial College ?1,117,026

22 TSB active projects (aluminium) This chart includes collaborative R&D

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.

Technology Inspired Innovation

Manufacturing

Resource Efficiency

Low Carbon Vehicles

2010

2011

2012

2013

2014

2015

Aluminium Matrix Composite Materials for vehicle Weight Reduction JLR, Composite Metal Technology, Antich ?2,115,281

A20X High Value Large Structure Casting Aeromet, LSM, JLR, JVM, U of Birmingham ?830,300

Hi-TINAL: Advanced High-Tin Aluminium Plain Bearing Alloys Rolls Royce, Brunel, KC Engineering ?542,682

Light weight 7.5 - 12 tonne Future Truck Chassis Concept Leyland Trucks, Sapa, MI Technology ?1,252,530

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

On-line control of Friction Stir Welding processes using ultrasonic testing Thompson Friction, TWI, Theta, GKN ?870,696

Aluminium Lattice Structures via Additive Manufacturing Econolyst, Alcon, Axon, Delcam, Delphi, Loughborough U, NottinghamU, Renishaw ?1,066,769

Recycled tolerant aluminium alloy utilising post consumer waste (REALCAR2) JLR, Innoval, Novelis, Aleris and Warwick University ?980,708

Ultra-light Car Bodies (UlCab) PAB, Impression Technologies, Lotus, Innoval, Imperial College ?1,117,026

23 REALCAR 2

REALCAR 2

Mechanical Biological Treatment (MBT)

Aluminium from MBT

EMR Media Separation

EMR Shredder

Aluminium RSIs

Aluminium Melting

DC casting

Coil rolling

Consortium Partners

24 Advanced Light Metals Processing Research Centre

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

25 Advanced Light Metals Processing Research Centre

Advanced Light Metals Processing Research Centre

Operational Q3 2014: 1300m2 approx

26 Summary

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

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