MAPP: EPSRC Future Manufacturing Hub in Manufacture using Advanced Powder Processes

使用先进的粉末工艺制造-MAP传统的材料成型和加工是巨大的浪费和能源密集型。即使有结构良好的材料流通战略来修复和回收工艺废料，能源使用，二氧化碳排放和相关的财务成本也越来越高，不可接受。我们不能再接受传统的制造模式，即过度使用能源和高水平的回收/降低昂贵和资源密集型材料的循环被视为不可避免的和规范，必须转向100%的起始材料被纳入工程产品，并对最终的关键性能充满信心。MAPP的愿景是实现粉末-基于制造工艺，提供低能耗，低成本和低浪费的高价值制造路线和产品，以确保英国制造业的生产力和增长。MAPP将通过创造新的、互联的、智能的、网络物理的制造环境来实现先进粉末加工技术的承诺，以实现“正确的第一次”产品制造。实现我们的愿景和实现这些技术的潜力将使我们能够实现减少能源消耗，材料使用和二氧化碳排放的社会目标，以及提高生产力，重新平衡英国经济，推动经济增长和财富创造的经济目标。我们已经制定了一个明确的战略，通过合作和跨学科的研究和创新计划，集中我们的集体努力，在以下主题中提供新的理解，行动和成果：1）颗粒科学和创新。粉末在其加工过程中将成为活性和设计的而不是被动的元素。对表面状态、表面化学、结构、本体化学、形态和尺寸的控制将产生针对工艺效率/可靠性和产品性能而设计的颗粒。表面控制将使我们能够保护过程外的颗粒并激活它们。了解颗粒属性和加工之间的影响将拓宽当前和未来制造平台的有限材料选择范围。2）集成过程监测、建模和控制技术。粉末加工的新方法将使我们能够处理颗粒的固有可变性及其随机行为。从先进的现场表征中获得的见解将有助于开发新的监测技术，以确保质量，并与建模方法相结合，从而实现优化和控制。用于自适应和预测性实时控制的数据流和处理将成为未来制造平台的组成部分，从而提高生产力和信心。3)可持续和未来的制造技术。我们的方法将为最终产品提供确定性和完整性，最终产品为净形或近净形，减少废料，降低能源使用和二氧化碳排放。将材料科学与制造科学重新结合将使我们能够实现现有技术的潜力，并开发新的本土制造工艺，以确保英国工业的繁荣。MAPP的重点和合作研究议程涵盖新兴的粉末制造技术：放电等离子烧结（SPS）、冷冻铸造、喷墨印刷、逐层制造、热等静压（HIP），以及激光，电子束，间接增材制造（AM）MAPP涵盖了广泛的工程材料，其中粉末加工具有明显的推动颠覆性增长的潜力-包括先进陶瓷，聚合物，金属，我们最初的应用是航空航天和能源领域-但必须解决常见问题。

Manufacture Using Advanced Powder Processes - MAPPConventional materials shaping and processing are hugely wasteful and energy intensive. Even with well-structured materials circulation strategies in place to recondition and recycle process scrap, the energy use, CO2 emitted and financial costs associated are ever more prohibitive and unacceptable. We can no longer accept the traditional paradigm of manufacturing where excess energy use and high levels of recycling / down cycling of expensive and resource intensive materials are viewed as inevitable and the norm and must move to a situation where 100% of the starting material is incorporated into engineering products with high confidence in the final critical properties.MAPP's vision is to deliver on the promise of powder-based manufacturing processes to provide low energy, low cost, and low waste high value manufacturing route and products to secure UK manufacturing productivity and growth. MAPP will deliver on the promise of advanced powder processing technologies through creation of new, connected, intelligent, cyber-physical manufacturing environments to achieve 'right first time' product manufacture. Achieving our vision and realising the potential of these technologies will enable us to meet our societal goals of reducing energy consumption, materials use, and CO2 emissions, and our economic goals of increasing productivity, rebalancing the UK's economy, and driving economic growth and wealth creation. We have developed a clear strategy with a collaborative and interdisciplinary research and innovation programme that focuses our collective efforts to deliver new understanding, actions and outcomes across the following themes: 1) Particulate science and innovation. Powders will become active and designed rather than passive elements in their processing. Control of surface state, surface chemistry, structure, bulk chemistry, morphologies and size will result in particles designed for process efficiency / reliability and product performance. Surface control will enable us to protect particles out of process and activate them within. Understanding the influence between particle attributes and processing will widen the limited palette of materials for both current and future manufacturing platforms.2) Integrated process monitoring, modelling and control technologies. New approaches to powder processing will allow us to handle the inherent variability of particulates and their stochastic behaviours. Insights from advanced in-situ characterisation will enable the development of new monitoring technologies that assure quality, and coupled to modelling approaches allow optimisation and control. Data streaming and processing for adaptive and predictive real-time control will be integral in future manufacturing platforms increasing productivity and confidence. 3) Sustainable and future manufacturing technologies. Our approach will deliver certainty and integrity with final products at net or near net shape with reduced scrap, lower energy use, and lower CO2 emissions. Recoupling the materials science with the manufacturing science will allow us to realise the potential of current technologies and develop new home-grown manufacturing processes, to secure the prosperity of UK industry.MAPP's focused and collaborative research agenda covers emerging powder based manufacturing technologies: spark plasma sintering (SPS), freeze casting, inkjet printing, layer-by-layer manufacture, hot isostatic pressing (HIP), and laser, electron beam, and indirect additive manufacturing (AM). MAPP covers a wide range of engineering materials where powder processing has the clear potential to drive disruptive growth - including advanced ceramics, polymers, metals, with our initial applications in aerospace and energy sectors - but where common problems must be addressed.