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Manufacture and characterisation of nanostructured lightweight alloys, in particular Al based alloys. Study of the microstructure and phase transformation processes of rapid solidified alloys, mechanical properties and their relationship with the microstructure.

• Hetherington Prize 2003
• Niobium Student Research Award 2004

Bulk nanostructured Al based alloys
H. Begg, Professor P.S. Grant
We are researching fibrular and laminate nanocomposites manufactured either by spray forming, casting, plasma spraying or powder processing, followed by high strain processing by extrusion. Systems of interest are primarily aluminium base and include both ultrahigh strength nanoquasicrystalline alloys ductilised with other Al alloy fibres and immiscible systems. Characterisation includes electron microscopy and X-ray diffractometry. Funded by EPSRC.

Piston development for high performance cars applications
Dr. M.L. Galano, Professor F. Audebert*, Professor G.D.W. Smith
Optimization of processing and composition of nanostructured Al based alloys for the development of automotive parts undergoing high strength at elevated temperature working environment. (*University of Buenos Aires, Argentina)

Metal matrix composites produced by semi-solid processing
G. Wu, Dr. K.A.Q. O'Reilly, Dr. M.L. Galano
This project is using semisolid processing to obtain novel graded properties and selective local reinforcement of Al alloy components. The processing is based on the rapid induction heating into the semi-solid state of cylindrical slugs of materials containing various fine-scale complex microstructures. Stacking of slugs of various compositions will be used to obtain the gradation in properties or local reinforcement. Semi-solid material will subsequently be injected into an Ube 350 tonne New Rheocaster to produce components. Semi-solid techniques are known to produce small, equiaxed, non-dendritic grains resulting in an increase in the toughness of the material. Materials manufactured by this route will be suitable for use at a wide range of temperatures, dependent on the the Al alloy system. The applications the project will be focusing on are engine blocks and automotive and machine components. Different types of nano-sized reinforcements will be used in order to optimise the properties achieved in the final components. The fine scale complex microstructures of the composites obtained will need to be characterised at the different stages of the processing to gain an understanding of the processing/microstructure relationship and the microstructural evolution, to provide a platform to control the complex microstructures and to understand mechanical behaviour.

3 public active projects

Cantor, B., Audebert, F., Galano, M., Kim, K.B., Stone, I.C. and Warren, P.J. (2005). 'Novel multicomponent alloys'. "Metastable, Mechanically Alloyed and Nanocrystalline Materials". Inoue, A. 24-25 1-5.

Metal matrix composites produced by semi-solid processing
K. O'Reilly / M. Galano / F. Audebert

The aim of this project is to use semisolid processing to obtain novel graded properties and selective local reinforcement of Al alloy components. The processing is based on the rapid induction heating into the semi-solid state of cylindrical slugs of materials containing various fine-scale complex microstructures. Stacking of slugs of various compositions will be used to obtain the gradation in properties or local reinforcement. Semi-solid material will subsequently be injected into an Ube 350 tonne New Rheocaster to produce components. Semi-solid techniques are known to produce small, equiaxed, non-dendritic grains resulting in an increase in the toughness of the material.

Materials manufactured by this route will be suitable for use at a wide range of temperatures, dependent on the the Al alloy system. The applications the project will be focusing on are engine blocks and automotive and machine components.

Different types of nano-sized reinforcements will be used in order to optimise the properties achieved in the final components. The fine scale complex microstructures of the composites obtained will need to be characterised at the different stages of the processing to gain an understanding of the processing/microstructure relationship and the microstructural evolution, to provide a platform to control the complex microstructures and to understand mechanical behaviour.

Also see homepages: Marina Galano Keyna O'Reilly

Development of aluminium matrix nanocomposites for high temperature applications
M Galano / F. Audebert

This project  is based on the development of Aluminium Matrix Complex Nanocomposties (AlMCNCs) with combinations of reinforcement strategies at the nanoscale that offer unique properties to target specific applications with an enhancement of combined properties i.e. increase thermal stability, ductility at forging temperature, and higher strength and Young’s modulus in higher performance applications. New materials will be used as nanoreinforcements for improving Young’s modulus and strength of nanoquasicrystalline alloys (NQX). Small Al-particles will be used as a plasticizer for improving the ductility of NQX alloys at forging temperature. These combinations of reinforcement strategies at the nanoscale will create unique complex nanocomposites with a unique combination of properties. Thus, a detailed study on the processing and the mechanisms responsible for microstructural stability and mechanical properties is required to develop these new Al matrix complex nanocomposites and to provide a platform for a disruptive knowledge for designing the right material for each application.
Several aspects will be developed within the project:
(i)    Investigation the different processing routes that lead to obtaining AlMCNCs in bulk shape for industrial applications.
(ii)    Development of bulk AlMCNCs with different combinations of exciting mechanical properties for producing high industrial impact.
(iii)    Testing of the new AlMCNCs in real applications

The project makes use of processing, microstructural characterisation facilities and expertise and draws on the latest alloy developments within the research group that offer genuine prospects for industrially useful nanomaterials. This project will be within an already running EPSRC project that is working on the development of bulk nanostructured alloy alloys and will run with the collaboration of several industrial partners representing a range of interests to pull through developed know-how.

Also see homepages: Marina Galano

Development of metal-metal matrix nanocomposites for hight strength applications
M Galano / F. Audebert

This project is based on the development of Metal Matrix Complex Nanofibril composites using new materials as reinforcements for improving Young’s modulus and strength of nanofibril alloys.  A combination of experimental and simulation studies will be carried out to help understanding of the optimum metal-metal combination, phase fractions, and processing conditions for obtaining the finest nanoparticles and nanofibers size
Several aspects will be developed within the project some of them with help of industrial and academic collaborators:
(i)    Investigation of the different processing routes
(ii)    Development of bulk Metal-Metal Matrix Complex composites with different combinations of exciting mechanical properties for producing high industrial impact.
(iii)    Modelling of the strengthening and deformation mechanisms at the nanoscale in order to predict the mechanical properties of the different composites types.
The project makes use of processing, microstructural characterisation facilities and expertise and draws on the latest alloy developments within the research group that offer genuine prospects for industrially useful nanomaterials. Strong industrial support is already in place for different aspects of the project in particular a company specializing in processing simulations will be carrying out the modelling for the different nanocomposites developed.

Also see homepages: Marina Galano

Also see a full listing of New projects available within the Department of Materials.