manchester.ac.uk/latest2

1. LATEST2 EPSRC PROGRAMME GRANT: LIGHT ALLOYS TOWARD ENVIRONMENTALLY SUSTAINABLE TRANSPORT Professor George E. Thompson: Principal Investigator www.manchester.ac.uk/latest2

2. EPSRC Programme Grant LATEST2 Light Alloys Towards Environmentally Sustainable Transport: 2nd Generation Solutions for Advanced Metallic Systems Award of £5.7 M over 5.5 years (10 July, 2010 to 9 January, 2016) Significant collaboration highlighted and leverage funding anticipated from a wide range of partners (industry, academia and research organisations)

3. LATEST2 -Integrated Interdisciplinary Team Principal and Co-Investigators: • Metallurgy • Materials Engineering • Chemistry • Chemical Engineering • Electrochemistry • Physics 8 Manchester staff members, including 4 Professors, 2 Readers, 1 Senior Lecturer & 1 LATEST2 Fellow (internationally recognised in their fields) plus associated academic staff from the School together with national and international collaborations Expertise: • Alloy Design • Deformation • Forming • Joining • Surface Engineering • Corrosion Control and Corrosion Protection • Performance Team completed with a Programme Manager, Outreach Officer and Administrative Assistant, and Technical support

4. Materials Activities in the School and Faculty • The Materials PerformanceCentre (2002) • The Northwest Composites Centre (2005) • The Manchester X-ray Imaging Facility (2009) • The Stress and Damage Characterisation Unit (2000) • Cross School Activities • University of Manchester Aerospace Institute (UMARI) • (Framework Agreement with Airbus completed in 2012) • Rolls-Royce Nuclear University Technology Centre • Nuclear Advanced Manufacturing Centre • EPSRC Programme Grant (NUMAN) • Diamond Light Source • BP Corrosion Laboratory plus chair position, & BP ICAM (International Centre for Advanced Materials) Hub • AkzoNobel Collaboration, plus AkzoNobel Laboratory and chair position established at Manchester • National Graphene Institute • Multidisciplinary Characterisation Facility

5. transport:CO2by 2020; LATEST2–Vision/Research Theme • Support dramatic reductions in the environmental impact of transport by facilitating a step change in high-performance light alloy design solutions in the automotive and aerospace industries. RoCO2 emissions => 95 g/km by 2020; • Address the key materials engineering issues and technologies required to enable introduction of a second generation of increased performance light alloy materials in more mass efficient products, utilising multi-material structures, and more complex components. architectures Vehicle transport roadmap: CO2 emissions to be reduced to 95 g/km by 2020 and then from 20% to 80% below 1990 levels by 2050; aviation, 50% of 2005 levels by 2020

6. Challenges,Themes and Theme Interactions Theme 2: Joining Advanced Alloys and Dissimilar Materials • Joining multi-material, high performance light alloy structures • Joining dissimilar material combinations • Modelling interface reactions, weld microstructures and performance Theme 1: Conquering Low Formability • Forming high performance light alloys and tailored panels • Advanced forming processes and methods (graded materials) • Modelling micromechanics of deformation, forming limits and surface finish Simulation, Modelling and Recyclability Theme 3: Surface Engineering for Low EnvironmentalImpact • Corrosion mechanisms at all length scales • In-service protection and cosmetic corrosion control • Surface engineering for adhesion/joint performance (e.g. composite to metal bonding) TWI Surfi-Sculpt TWI Surfi-Sculpt Output and Technology Transfer Enabling knowledge for manufacturing advanced light alloy materials and their interfacing in multi-material systems, with more complex, mass efficient, design architectures

7. LATEST2- Multi-Material Design Magnesium Aluminium Steel Carry-over Plastic EC - Superlight Car Project (SCP): 37% Weight Saving Berger, Lesemann & Sahr, 7th European LS-DYNA Conf (2009) Joining and corrosion protection are challenges for multimaterial car body design (Dilthey & Stein, Sci. & Tech. of Welding and Joining, 11, 135-142 (2006)) Further requirements: • Increased performance light alloys integrated in multi-material designs • Reduced energy, environmentally-compliant manufacturing processes • Increased use of recycled materials, greater service life, enhanced functionality • Accelerated time to market, enhanced modelling and simulation tools Lesemann, Brockerhoff & Urban, AZTautotechnology, 8,16-20 (2008)

8. ALIGNMENT WITH EPSRC STRATEGY EPSRC HAS THREE CLEAR GOALS OF (i) SHAPING CAPABILITY, (ii) DEVELOPING LEADERS & (iii) DELIVERING IMPACT (SPONSOR NOT FUNDER!) • CAPABILITY • IMPACT • SKILLS • RESEARCH LEADERSHIP • PARTNERSHIP • CREATIVITY • FUTURE CHALLENGES • FOCUS • EXCELLENCE • Global, Economic and Societal • Challenge Themes, including: • Manufacturing the Future-EPSRC • Energy-RCUK Cross Council • Theme (low carbon innovation group) • Increased collaboration through Doctoral • Training (Advanced Metallics Systems • with Sheffield) EPSRC is at the heart of discovery and innovation; its research saves lives, creates prosperity, protects the environment and inspires future generations. EPSRC is pioneering research and skills for the future. The research ranges from physics, chemistry and mathematics to materials computing, engineering and high value manufacturing

9. LATEST2 Research Facilities • Processing and Formability: Theme 1 • Rolling mill; 250 mm rolls for hot and cold rolling • ECAE press and SPF press • Plane strain compression rig • Erichsen 145-60 sheet forming press with image correlation strain measurement • Full range of torsion/tension/compression testing over large range of temperatures • In-situ deformation and heating - SEM • Material Characterisation Facilities: SEM/EBSD coupled with FIB,   XRD and X-ray microtomography

10. Joining: Theme 2 • 25 kW friction stir welding • Friction stir spot welding • Ultrasonic spot welding (Sonobond) • Weld process instrumentation – e.g. thermal imaging • Weld simulators (EMT/Gleeble) • Range of modelling tools, developed in-house and commercial (e.g. THERMOCALC) • Material Characterisation Facilities • Advanced microstructural analysis (dual beam FIB, FEG-TEM, FEG-SEM EBSD etc) LATEST2 Research Facilities

11. LATEST2 Research Facilities • Surface Engineering: Theme 3 • Surface analysis/elemental depth profiling (XPS/GDOES) • Electron probe microanalysis (Earth, Atmospheric & Environmental Sciences) • Image assisted electrochemical probing (ENA), accelerated testing • (salt spray / humidity chambers) • Magnetron sputtering for model alloy generation / coating development • SPM/SKPFM probing • Waveform generators for coating by plasma electrolytic oxidation • High resolution, low kV, backscattered scanning electron microscopy / ESEM aligned to X-ray tomography/ electron tomography (in-situ serial sectioning) • Laser surface processing (80 W/2 kW KrF Excimer • Slab Rofin CO2 lasers) • Total and diffuse reflectance • Local electrochemistry, including SVET • Advanced microstructural analysis • Dual beam FIB, FEG-TEM, FEG-SEM EBSD etc)

12. Research Facilities/Collaborative Activities • In-situ loading experiments using neutron and synchrotron • X-ray diffraction and diffraction contrast tomography (ESRF, ISIS); • other synchrotron sources plus UK Diamond facility • HZG in-situ microstructural analysis of FSW - on FlexiStir • Heriot Watt CIM on Laser-based Production Processes • University of Kaiserslautern – USW of Al-Ti • Cranfield on ALM and dissimilar joining • Cambridge University Engineering on process modelling • Beijing Institute of Aeronautical Materials/CSIRO – cold spray coatings • University of Paris, Jussieu- Van de Graaf Generator, Nuclear Reaction Analysis, Rutherford Backscattering Spectroscopy • Brunel University- Liquid Metal Engineering • Loughborough University-Hybrid Machining and Turning • Dimokritos (Greece)- Nanocontainers(including Inhibitor-filled containers) • FEI- Real Time Electron Microscopy with Brookhaven National Laboratory • Daresbury-SuperStem (Liverpool) • University of Huddersfield-MEIS and metrology • Poeton-industrial scale-up of anodizing processes/ Goodrich-fatigue • University of Swansea- local electrochemistry, e.g. Kelvin probe and scanning vibrating electrode studies • Manchester laser surface finishing facilities

13. Theme Interactions (multi-disciplinary approach) Tailored Panels Additive Manufacturing Forming & Micromechanics Joining High strength aluminium alloys Surface engineering for adhesive bonding Appearance, Near-surface deformed layers, Environmental degradation Composite / metal joints Corrosion monitoring & protection of dissimilar joints Surface Engineering & Corrosion Analytical Techniques

14. Scope of Characterisation SEM Imaging with EDS and EBSD TEM / STEM tomography Light Microscopy Raman 2D imaging 3D EBSD X-Ray Tomography TEM / SEM Tomography 3View X-ray Nano-tomography 3D Tomography FIB TEM Environmental Stages X-ray Environmental stages SEM Environmental stages mm μm nm Sub - nm NikonCT XradiaMicroCT XUM FIB/SEM 3View TEM/Atom probe

15. Modelling of laser welding • Airbus-Wing of the Future Metallics Programme • Deformation of CPH Materials • Laser Enhanced Manufacturing • EADS -TRL Upgrade • BAE Systems- Land Systems • BP Aerospace- Consultation • TARF-LCV • HITEA-TSB • Constellium • AVIC China • ONR, USA • SAPA Extrusions • BP- Self Healing Coatings • Airbus Case Award • Further discussion and consultation: • Akzo Nobel, (ii) BAE SYSTEMS- Wing of the Future, Carbon Allotropes, (iii) Fokker- Consultation- anodizing, (iv) Naples/Alenia, cold spray, smart coatings and anodizing, (v) GATAN/FEI, high resolution tomography and 3D imaging, (v) CSIRO Australia, (vi) TWI, (vi) Academia in Colombia & Chile, (vii) Brunel LATEST2-Progression/Sustainability

16. LATEST2-Research Programme Overview • 3 Interdisciplinary Research Themes • 23 research topics with 3 new topics introduced from the start of the research programme • 140 research projects • 21 research projects directly funded and 119 added value • 72 completed research projects

17. LATEST2-Resource Overview • Administrative Team • Project Manager, Outreach Administrator, Programme Administrative Assistant, 50% directly funded, 50% added value • Technical Team • 7 technicians, 2 directly funded, 5 added value • Research Team • 1 PI, 6 Co-Investigators, 2 associated Co-Investigators • 2 Research Fellows, 1 directly funded, 1 added value • 12 PostDoc RA, 6 directly funded, 6 added value • 50 PhD Studentships, 8 directly funded, 42 added value • 12 CDT PhD Studentships, 4 directly funded, 8 added value • 29 MSc Studentships added value • 4 EngD Studentships added value • 8 MEng Studentships added value • 25 Visiting Scientists added value • 2 Research Assistants • Note: Scientific visitors contribute short term project work ranging from 1 – 6 months.

18. LATEST2: Prizes and Awards to Researchers, and Publications (Impact ) • 2012: IOM3 Grunfeld Memorial Award and Prize (J. Robson) • : IOM3 Colin Humphreys Education Award (A. Laferrere (& J. Smith)) • 2013: IOM3 Grunfeld Memorial Award and Prize (M. Preuss) • 2012: First Prize in poster contest at 15th Conference on Corrosion and Corrosion Protection of Metals, Czech Republic, (A. Nemcova, • P. Skeldon & G. E. Thompson) • 2013: Jim Kape Memorial award of the Institute of Materials Finishing for most significat aluminium based paper published in Trans. I. M. F. (M. Curioni, P. Skeldon & G. E. Thompson) • 209 publications from 2010 to August, 2013 in prestigious, international journals with academic and industrial collaborators as appropriate

19. LATEST2-Outreach Overview • Organised a wide range of outreach activities to communicate • the work of LATEST2, EPSRC and Engineering & Physical Sciences • Target audiences include: • Industry, Academia, Schools Pupils, Teachers and Career Officers and the general public • Undertaking specific tailored activities to successfully reach our identified target audiences with relevant science communications • Reached the following target audience contact points since the LATEST2 Programme commenced in July 2010 • Schools and colleges: 5400 • Industry and Academia : 2300 • Community : 157000 • Currently securing additional funding and developing new initiatives to drive the IMPACT forward

20. LATEST2: SUMMARY • Research activities directed to an important strategic research • theme and manufacturing base- shaping capability (focus on UK • strengths). Alignment with TSB and related collaboration to • accelerate exploitation (increased TRL and scale up) • Key challenges identified and reviewed, and addressed in • innovative research packages with national and international • collaborators- shaping capability and delivering impact (focus on • challenges) • Creating and sustaining research scientists and engineers in the) • UK and beyond- establishedleaders and developing leaders (CDT) • Ambassador roles for materials in engineering and physical • sciences through extensive outreach activities- delivering impact