Rapid Product Development through Process Innovation

通过流程创新快速开发产品

• 批准号: EP/P020755/1
• 负责人: Claire Davis
• 金额: $ 114.8万
• 依托单位: University of Warwick
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2017
• 资助国家: 英国
• 起止时间: 2017 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FP020755%2F1
• 关键词: Rapid; Product; Development; through; Process

Steel is the most used material in the world by value, one of the most recyclable materials and the only metal produced and consumed in volume in the UK. It is a foundation industry underpinning the economy, e.g. Tata Steel provides the most material for Nissan Leaf's lightweight body and in construction the UK is set to lead the growth rate at 2.8% (cf. EU average of 1.8%). However, the UK steel industry currently faces high energy and raw materials costs with some inefficient processes that are unable to produce advanced products. A strong research base is essential to support the UK steel industry, users of steel and steel-hybrid materials and to develop the skilled workforce needed to drive innovation. There is strong industrial need from the UK transportation and yellow goods industry for material innovation leading to lightweighting, superior performance and establishment of a UK supply chain for auto-bodies, transmissions, battery casings etc; and from the UK construction sector where half of construction demand will be in the residential sector by 2030. There is massive potential for novel steel-based solutions such as hybrid materials, which require detailed understanding and control of the steel surface properties during processing.To reduce lead-times for alloy innovation, and to ensure new alloys can be processed, rapid alloy design and high-throughput processing is required. Whilst combinatorial approaches for identifying an alloy for desired properties are available, the ability to rapidly simulate all the transient process steps critical for actual alloy manufacturing and its integration into structures and devices does not exist. Therefore a suite of new equipment is proposed that will identify and accelerate inventions for synthesizing alloys encompassing rapid processing, characterisation and modelling. The equipment will comprise a high throughput 3D ingot printer, drop furnace to assess liquid-environment reactions for solidification optimization, surface/bulk deformation rig to assess solid-environment reactions for hot process optimization, high throughput rolling to produce appropriate microstructures for subsequent testing, PVD deposition to enable co-development of compatible coatings and electro-thermal-mechanical testing for coating, welding and forming assessment. We will access existing characterisation (SEM and Raman/AFM) facilities off line to enable detailed assessment of bulk and surface structure of down selected systems. Alongside this will be modelling software for bridging the gaps from laboratory high-throughput experiments to manufacturing processes. The equipment requested was identified following extensive engagement and discussions with industrial partners, particularly Tata Steel who have made very significant commitments, and the Tata Steel network of supported UK academics.The facility will be managed by a dedicated test facilities engineer with a booking system for access for individual equipment items and as a through process assessment tool for new alloy systems. A Steering Group and Industrial Advisory Group will meet regularly to ensure that high quality scientific projects are prioritized, industrial use is encouraged and fair access is maintained. WMG has extensive experience of providing equipment support and user training and have strong links with industry through the High Value Manufacturing Catapult, co-location of the Tata Steel UK R&D centre and the new National Automotive Innovation Centre. Ongoing EPSRC projects have been identified that will immediately benefit from the facility with new research areas being developed in collaboration with industry and other academics.We feel that the development of this facility will be a critical element in developing an environment where the essential technologies needed for transforming the UK steel industry can be invented and implemented utilizing energy and raw material flexible processes and develop high value products

钢铁是世界上使用价值最高的材料，也是最可回收的材料之一，是英国唯一大量生产和消费的金属。它是支撑经济的基础产业，例如，塔塔钢铁为日产聆风的轻量化车身提供了最多的材料，在建筑业，英国将以2.8%的增长率领先（参见平均1.8%）。然而，英国钢铁行业目前面临着能源和原材料成本高企的问题，一些低效的工艺无法生产出先进的产品。强大的研究基础对于支持英国钢铁行业、钢铁和钢铁混合材料的用户以及培养推动创新所需的熟练劳动力至关重要。英国运输和黄色物品行业对材料创新有强烈的工业需求，导致轻量化，上级性能和建立英国汽车车身，变速器，电池外壳等供应链;英国建筑行业到2030年一半的建筑需求将在住宅领域。新型钢基解决方案（如混合材料）具有巨大的潜力，这需要在加工过程中详细了解和控制钢的表面特性。为了缩短合金创新的交付周期，并确保新合金能够加工，需要快速合金设计和高产量加工。虽然用于识别合金所需性能的组合方法是可用的，但快速模拟对于实际合金制造及其集成到结构和器件中至关重要的所有瞬态工艺步骤的能力并不存在。因此，提出了一套新设备，将识别和加速合成合金的发明，包括快速加工，表征和建模。该设备将包括一台高吞吐量3D铸锭打印机，用于评估凝固优化的液体环境反应的落炉，用于评估热工艺优化的固体环境反应的表面/体积变形装置，高吞吐量轧制以产生适当的微观结构用于后续测试，PVD沉积以实现兼容涂层的共同开发以及用于涂层，焊接和成型评估的电热机械测试。我们将访问现有的表征（SEM和拉曼/AFM）设施离线，使详细评估的体积和表面结构的下选定的系统。除此之外，还将推出建模软件，用于弥合从实验室高通量实验到制造过程的差距。经过与工业合作伙伴的广泛接触和讨论，特别是做出了非常重要承诺的塔塔钢铁公司，以及塔塔钢铁公司支持的英国学者网络，确定了所需的设备。该设施将由一名专门的测试设施工程师管理，并通过预订系统访问单个设备项目，并作为新合金系统的全过程评估工具。指导小组和工业咨询小组将定期举行会议，以确保高质量的科学项目得到优先考虑，鼓励工业使用，并保持公平的准入。WMG在提供设备支持和用户培训方面拥有丰富的经验，并通过高价值制造弹射器，塔塔钢铁英国研发中心和新的国家汽车创新中心的共同定位与行业建立了密切的联系。正在进行的EPSRC项目已经确定，将立即受益于该设施，与工业界和其他学术界合作开发新的研究领域。我们认为，该设施的发展将是一个关键因素，有助于创造一个环境，使英国钢铁工业转型所需的关键技术能够利用能源和原材料灵活的工艺加以发明和实施，并开发高价值产品

项目成果

Optimising compression testing for strain uniformity to facilitate microstructural assessment during recrystallisation

• DOI: 10.1016/j.rinma.2021.100218
• 发表时间: 2021-09
• 作者: C. Slater;N. Tamanna;C. Davis

Effect of Sample Geometry on Strain Uniformity and Double Hit Compression Tests for Softening Kinetics Determination

• DOI: 10.1002/srin.202200157
• 发表时间: 2022-08-18
• 期刊: STEEL RESEARCH INTERNATIONAL
• 影响因子: 2.2
• 作者: Tamanna，Nusrat;Slater，Carl;Davis，Claire
• 通讯作者: Davis，Claire

A Scale-up Study on Chemical Segregation and the Effects on Tensile Properties in Two Medium Mn Steel Castings

• DOI: 10.1007/s11661-021-06533-w
• 发表时间: 2021-10
• 期刊: Metallurgical and Materials Transactions A
• 作者: T. Kwok;C. Slater;X. Xu;C. Davis;D. Dye

Near Net Shape Casting: Is It Possible to Cast Too Thin?

• DOI: 10.1007/s11663-020-01964-z
• 发表时间: 2020-09
• 期刊: Metallurgical and Materials Transactions B
• 作者: C. Slater;C. Davis

Rapid alloy prototyping for strip steel development: DP800 steel case study

带钢开发的快速合金原型：DP800 钢案例研究

• DOI: 10.1080/03019233.2021.1880036
• 发表时间: 2021
• 期刊: Ironmaking & Steelmaking
• 影响因子: 2.1
• 作者: Zhu Y