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Aluminium Research for Road Transport Applications

This research focuses on the use of aluminium in road transport applications, including aluminium intensive vehicles and the development of lightweight aluminium structures. It also examines the growth of aluminium automotive sheet production and continuous heat treatment capacity.

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Aluminium Research for Road Transport Applications

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  1. Aluminium Research for Road Transport Applications Geoff Scamans Innoval Technology and Brunel University

  2. Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993 BL Metro 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. Bertone Fiat X1/9 AIV Five AIV replica Bertone Fiat X1/9s were built in 1986 using AA5251 sheet for the monocoque and AA6010 for the closure panels. Ford Taurus/Sable 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.

  3. Range Rover Sport

  4. Range Rover Sport

  5. Current JLR Aluminium Applications

  6. 350 Petrol 300 Land Rover TD V8 250 200 Land Rover TD V6 CO2 g/km Diesel 150 Petrol Hybrid 100 50 0 0 500 1000 1500 2000 2500 3000 Curb Weight kg Passenger Vehicle Emissions (ICE) 2012 UK vehicles

  7. EU Aluminium Automotive Sheet Production Growth (kt) body structures (20%) closures (80%)

  8. 700 TBC Novelis Sierre2 600 AMAG, Ranshofen Hydro, Grevenbroich 500 Constellium, Neuf Brisach Aleris, Duffel 400 Novelis, Sierre Novelis, Nachterstedt 300 200 100 0 2006 2008 2010 2012 2018 2020 2016 2000 2002 2004 2014 EU Growth in Aluminium Automotive Sheet Continuous Heat Treatment Capacity (kt)

  9. Alcoa Heat Treatment and Finishing: Davenport

  10. 1000 TBC 900 Alcoa, Knoxville 800 Novelis, Oswego 700 Alcoa, Davenport Alcoa, Danville 600 Novelis, Kingston 500 400 300 200 100 0 2016 2018 2020 2006 2008 2010 2012 2000 2002 2004 2014 NA Growth in Aluminium Automotive Sheet Continuous Heat Treatment Capacity (kt)

  11. Jaguar F-type

  12. 300.0 2012 2015 250.0 2020 2025 200.0 150.0 100.0 50.0 0.0 Crash Chassis Body 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

  14. 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 Key: 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 Strategic Affordable Manufacturing in the UK through Leading Environmental Technology (SAMULET) 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 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. 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 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

  15. 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 Steel & Al Light Alloys Towards Environmentally Sustainable Transport LATEST2 – Thompson - Manchester – £5,762,121 Fellowships Key: Light Metals Programme Grants Centre for Innovative Manufacturing: Liquid Metal Engineering Brunel/Oxford/Birmingham –- £5,119,391 Centre for Innovative Manufacturing Al & Mg Responsive Funding 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 Grain refiner for high performance light metal castings Babu Nandela – Brunel £121,144 Al Energy saving in the Foundry Industry Jolly – Cranfield £116,344 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. 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 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

  16. Towards Affordable, Closed-Loop Recyclable Future Low Carbon Vehicle Structures:Metallic Materials Group Objectives BCAST, Brunel University Geoff Scamans

  17. Research Vision and Ambition 2011 2030

  18. 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. 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

  20. 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 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 Upcycling of Light Alloys by Rheoforming Scrap (ULARS) Innoval, Meridian, Norton Aluminium, Zyomax and Brunel £1,614,996 Environmental Sustainability Recyclable Ultra Light Mixed material Automotive Platform (RULMAP) Innoval, IQuad, Atlas Composites, Boal and Oxford £768,317 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 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 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 Warm Aluminium Forming Technology (WAFT) JLR, Dutton, Innoval, Novelis, Stadco, Whiston, Fuchs and Imperial £2,842,974 Highly Innovative Technology Enablers In Aerospace 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 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. 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 Innovative Microstructural Design for Advanced Al Alloys (IDEAL) Rolls-Royce, Aeromet, University of Birmingham £569,453 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 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 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 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

  21. 2010 2011 2012 2013 2014 2015 Aluminium Matrix Composite Materials for vehicle Weight Reduction JLR, Composite Metal Technology, Antich £2,115,281 Technology Inspired Innovation A20X High Value Large Structure Casting Aeromet, LSM, JLR, JVM, U of Birmingham £830,300 Manufacturing Hi-TINAL: Advanced High-Tin Aluminium Plain Bearing Alloys Rolls Royce, Brunel, KC Engineering £542,682 Resource Efficiency Light weight 7.5 - 12 tonne Future Truck Chassis Concept Leyland Trucks, Sapa, MI Technology £1,252,530 Low Carbon Vehicles 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 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. 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 2010 2011 2012 2013 2014 2015

  22. REALCAR 2 Mechanical Biological Treatment (MBT) Aluminium from MBT EMR Media Separation EMR Shredder Aluminium RSIs Aluminium Melting DC casting Coil rolling Consortium Partners

  23. 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

  24. Advanced Light Metals Processing Research Centre Operational Q3 2014: 1300m2 approx

  25. 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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