Structural Materials - Matuk.co.uk
Structural materialsMaterials UKOwned by the materials communityScience and Technology Working GroupStructural materials
Structural materials -A Science and Technology ReportThis report on structural materials has beenproduced as part of the Materials UK. Itfollows a series of consultations, discussionsand meetings, which sought to engage witha broad cross-section of the UK structuralmaterials community. This involved townhall meetings, focus group meetings anddiscussions with the Materials KTN.3Materials UK Energy Review 2008 - Multifunctional materials
ContentseXecutIve summary31 IntroductIon52 scope73 osItes3.2.13.2.23.2.33.2.43.2.53.3Importance and value to uKKey driversr&d prioritiesBarriersKey recommendationsconstructIon materIals3.3.13.3.23.3.33.3.43.3.53.4Importance and value to uKKey driversr&d prioritiesBarriersKey recommendationsImportance and value to uKKey driversr&d prioritiesBarriersKey recommendationsother materIal classes4 dIscussIon and 111112121213131415151517171818191920appendIX 121acKnoWledGements22
Structural materials make asignificant contribution toemployment and GDP in the UK.They represent a highly diverse andstrongly multidisciplinary area, withlinks to numerous industrial sectors.2Materials UK - Structural materials
Executive SummaryOf all material classes, structuralmaterials, make a significantcontribution to employment and GDPin the UK. They represent a highlydiverse and strongly multidisciplinaryarea, with links to numerous industrialsectors such as aerospace, energy,construction, automotive, leisure,security and defence. the need to improve the modellingof materials through the full lifecycle (alloy design, production,processing, manufacture and enduse) including lifetime prediction. the requirement for bettercondition monitoring and NDEof structural materials and theirmanufacturing processes.Structural materials comprise a numberof classes such as metals (ferrousand non-ferrous), composites (eg.ceramic, metal and polymer matrix),construction materials (eg. glass,concrete, steel, ceramics, wood) andothers such as structural & refractoryceramics and polymers. Whilst therange of materials may be diverse,many common technical challengeshave been identified: the drive for lower cost throughinnovative production andprocessing methods. the need for technology transferbetween materials sectors andthe implementation of novelalternative uses for existingmaterials. the need for materials towithstand more aggressiveenvironments eg. extremetemperatures, stresses, impactand weather conditions. the requirement to reduceenvironmental impact both intheir production, end-use andrecyclability. the need to understand completematerials ‘systems’ (eg coatedcomponents, sandwich structures,composites, joints)Historically, significant benefitshave been gained by ‘incremental’developments in structuralmaterials. This philosophy must bemaintained and supported, whilst anenvironment for the developmentof applicable ‘disruptive’ technologiesis encouraged in the longer termthrough the UK research base.Despite the UK being a worldleader in many sectors involvingthe development and utilisationof structural materials, such as inaerospace, energy, F1racing, etc, theygenerally have an image of being‘low-tech’ which impacts on thelevel of priority and support theyreceive and also on recruitmentinto the sector. Such an image isprofoundly inaccurate and MaterialsUK (MatUK) and the MaterialsKnowledge Transfer Network (KTN)should raise the profile of structuralmaterials and promote an ‘integrated’approach involving industry, researchcouncils, government and RegionalDevelopment Agencies (RDAs).A sustainable long-term strategyshould be put in place that willensure the promotion of thestructural materials sector, provideincreased added value throughthe development of cross-sectorsynergies, facilitate technologytransfer and ensure the alignmentof R&D priorities. All of this mustbe underpinned by a sustainablefunding strategy.Strong market drivers currently exist todevelop value added products acrossa number of sectors. For example,structural materials have a majorrole to play in tackling a number ofcurrent economic and environmentalchallenges around a number of UKGovernments low carbon strategiesfor tackling climate change and creatinga low carbon economy. The supportand development of the UK as a worldleader in many aspects of structuralmaterials will provide an excellentopportunity to exploit these markets.3
Structural materials have links tonumerous industrial sectors suchas aerospace, energy, construction,automotive, transport, leisure,packaging, security and defence, all ofwhich are important to the sustainabilityand growth of the UK economy4Materials UK - Structural materials
1 IntroductionOf all material classes, structural materials make a significantcontribution to employment and GDP in the UK. Theyrepresent a highly diverse and strongly multidisciplinary area,with links to numerous industrial sectors such as aerospace,energy, construction, automotive, transport, leisure,packaging, security and defence, all of which are importantto the sustainability and growth of the UK economy. Forexample, the Governments Energy Policy1, legislation onzero carbon homes3 and its Low Carbon Industrial Strategy2‘investing in a low carbon Britain’ illustrate a number ofmarket opportunities where structural materials will play a keyrole in helping to achieve technology challenges around a lowcarbon economy.This report on structural materials has been produced aspart of the Materials IGT initiative and has provided input,both into the Science and Technology Task Group Reportand the IGT final report. It follows a series of consultations,discussions and meetings, which sought to engage witha broad cross-section of the UK structural materialscommunity. This involved town hall meetings, focus groupmeetings and discussions with the material KTNs. The inputhas been considered and consolidated into a set of specificrecommendations for the future development of this partof the materials sector. It has also provided input into theTechnology Strategy Boards Advanced Materials Strategythrough which some of its recommendations could beimplemented in the future. Whilst it is recognised that thisreport, given the broad scope of the technology area, hasnot been able to capture all possible points of view, manycommon challenges and synergies have been identified andare reflected herein.5
The term ‘structural materials’is defined to be any material ormaterial ‘system’ whose primaryfunction is to be load or stressbearing, often under extremeenvironmental conditions.6Materials UK - Structural materials
2 ScopeIn the context of this study, the term ‘structural materials’ is defined to be anymaterial or material ‘system’ whose primary function is to be load or stress bearing(induced either mechanically, thermally or a combination of both); often underextreme environmental conditions. The scope of this report also covers issuesrelated to the production, processing, manufacture, end-use and recyclability ofstructural materials. Although there are clear synergies and overlapping areas withother material classes such as functional, multi-functional and bio-materials, theseare the subject of other reports. It is recognised that many common issues will arisewith these other material classes and this will only help to define and substantiatesubsequent outputs and recommendations of the KTNs and Materials UK. Thescope of this report has therefore been limited to:Metals (includingsurface-treated ferrousIntermetallic systemsGlassConcreteCeramicsWoodConstructional SteelCMC’sPMC’sMMC’sFor each of these classes, the following key issues have been addressed:Importance and valuean attempt to assess the industry in terms of employment, turnover and opportunitiesKey driverseg. technical, socio-economic and regulatoryR&D prioritiestechnology priorities for the UKBarrierseg. technical, socio-economic and regulatoryKey recommendationspriority areas to be taken forwardA brief section is also included that recognises the importance of other classesof material not falling into the above three categories, such as structural andrefractory ceramics and non-reinforced polymers.7
3 Findings3.1 Metals3.1.1 Importance and ValueThe UK currently produces around14 million tonnes of steel, 1.2 milliontonnes of castings and 500,000 tonnesof aluminium per year. In addition,metals manufacturing creates 18billion of added value for the UKeconomy, equivalent to 11% of allUK manufacturing and employs over404,000 people in the UK. Whilst thegreatest proportion of this is relatedto the steel and aluminium industry,contributions are also made from thetitanium, magnesium, nickel and copperindustries. Each year these businessessell a combined total of 47 billion ofmetals into engineering, construction,automotive, aerospace, energy andother manufacturing sectors. All ofthese sectors, and the companies withinthem (some of whom are recognisedas world-leaders and represent a majorsource of employment and GDP inthe UK), are dependent on the supplyof high quality structural metals in themanufacture of their products. A moredetailed breakdown of the UK metalssector is shown in Appendix 1.Recent strong demand, particularlyin ferrous materials, has led to aturnaround for parts of the UK metalssector. However, issues of mineral oresupply and rising energy prices meansthat the UK metals industry mustcontinue to strive for production andsupply chain efficiencies to delivercompetitively priced materials that theircustomers need in order to succeed intheir respective markets.Regarding the environment, which is akey national and global issue, the fact8Materials UK - Structural materialsthat metals are highly recyclable meansthe sector is also central to the UK’ssuccess in achieving environmentalsustainability.rates is exemplified by the fact thatin 2004 the rate of recycling ofaluminium-based packaging in the UKwas only 28%.3.1.2 Key DriversA second major driver is costreduction. It is evident thatcompetition from low-cost countriesis impacting large parts of the UKmetals sector and there is a constantneed to drive down costs whilstimproving quality. To optimise thecost reduction opportunities it isessential that the whole life cycle ofthe products is considered from alloyproduction, processing, manufactureand end-use through to recycling.Whilst it may be difficult to competeon cost alone in certain areas, theUK is able to demonstrate a historyof creating innovative solutions thatprovide effective cost reductionopportunities. Considerableopportunities remain within the‘conventional’ processing area toachieve cost reduction; through theapplication of improved modellingand design, and the application ofhigh precision forging, forming androlling processes; and the applicationof novel processing techniques (i.e.laser forming, spin extrusion, etc.).Similar opportunities exist withinthe ‘conventional’ casting sector toreduce both the time to marketand production cost through theapplication of rapid prototyping, forthe production of inserts and cores,and the introduction of thin wall castingtechniques.These more evolutionarydevelopments have more recently beenaugmented by the development andapplication of a range of novel nearnet shape processes, such as: metalThe key drivers identified for thesector are those of environment,cost, the creation of value addedand government legislation.Environment is currently seen asthe priority driver for the structuralmetals industry. This arises from theneed to significantly reduce CO2emissions either through reducedfuel consumption or throughthe use of more environmentallyfriendly production and sustainablemanufacturing processes. Reducedfuel consumption can be achievedthrough ‘light-weighting’ of structures,particularly for the transport,aerospace and military sectors, or bythe burning of fuel more efficiently forenergy production through the useof higher temperature alloy systems,such as those required for powergeneration, aerospace gas turbinesand automotive engines. In termsof production and manufacturing,emissions can be reduced throughthe introduction of more efficientprocesses and procedures and by theintroduction of benign downstreamprocesses, such as finishing andcoating. By further embracing theprinciples of sustainable manufacturing,new technologies which maximisethe capacity for recovery, recycling,waste reduction and the sustainableutilisation of resources and rawmaterials will also contribute to animproved environment. The scope toachieve greater recovery and recycling
injection moulding, hot isostatic pressing,laser sintering, and other additive layerprocesses.The UK metals and metalsmanufacturing community has much togain from the appropriate application ofthese tools.reflect the above strengths of the UKskill-base and look to build upon them.The priority areas for the UK are: The provision of value added tothe market was also identified asa key driver which the UK metalsindustries should address. The need toprovide product differentiation in themarket place, and the need to meetstringent legislative and environmentaltargets, continually creates theopportunity for innovation and thecreation of custom built solutions tothe end user.Legislation in certain parts ofthe industry is also seen as a majordriver. The need to meet increasinglystringent environmental demandshas been dealt with above; however,additional regulation and health andsafety legislation also have a keyimpact in certain sectors; specificallyin the manufacturing, oil & gas andprocessing industries. 3.1.3 R&D PrioritiesThe UK still has world-class expertisein the development of many metallicsystems, including steels, aluminium,high temperature superalloys, titanium,and magnesium. Supporting thisexpertise there is an extensive R&Dinfrastructure, providing a strong andinnovative platform of skills in design,structural integrity, surface engineering,powder metallurgy, modelling, processdevelopment, fabrication and joining.Therecommended R&D priorities largely development of metallic systemsto withstand more arduousoperating conditions; includinghigher temperatures, impactloading, thermal and mechanicalstresses and more aggressiveenvironments. All these willenable increases in componentlifetime, reliability, efficiency andreduce the impact of the harshenvironments on the operatingcomponents. This was seen as amajor cross-sector priority.development of novel production,manufacturing and inspectionprocesses aided by the utilisation ofon-line process control, conditionmonitoring and NDE, which willlead to significantly enhanced quality,improved properties, reduced cost,increased output and betterproduct reliability.to build on the strong existingskill-base in modelling to evaluatethe full life cycle of materialsfrom alloy design, throughto production, processing,manufacture, lifetime prediction,end-use and recycling. This canhave a major impact in reducingtime-to-market, increasingsustainability and reduced full lifecycle cost and cost of ownership.to design, develop and introducelight-weight, high performancestructures; particularly for use inthe defence and transport sectors. the development of highperformance coatings and surfacetechnologies for metallic systemsare essential in creating highvalue added components andsystems, including the creation ofmultifunctional and SMART systemsA key generic recommendationin the area of structural metals isthe need to recognise and support‘incremental’ innovation in the sector.The continuous optimisation of alloycompositions or coating processeshave historically lead to significantimprovements in strength, impact,wear, corrosion and oxidationresistance which has helped maintainthe UK’s leading position in manysectors particularly automotive,aerospace and energy.Not withstanding the above, it is stillwidely recognised and recommendedthat an environment must also bepromoted within the UK researchcommunity that still encourages theinnovative development of ‘disruptive’technologies that can lead to thestep-change demonstration andimplementation of world-beatingtechnologies.3.1.4 BarriersThere are a number of barriersrecognised within the structuralmetals sector, not least that they areperceived as being a well establishedtechnology with little scope forfurther development. For this reason,it has not historically been seen as apriority area for R&D funding by thegovernment or research councils. For9
The environment is currentlyseen as the priority driver forthe structural metals industry.10Materials UK - Structural materials
the reasons mentioned previously thisshould not be the case and both thevalue of incremental improvementsand the overall value of structuralmetals to the UK must be betterrecognised. This will require theimplementation of a coherent longterm strategy and funding mechanisminvolving industry, government,research councils and RDAs tosupport the area.The globalisation of the supplychain and reduced UK supply basemeans that many of the requireddevelopments for structural materialsare outside the control of UKindustry. This has led to a lack ofintegration between alloy producers,processors, manufacturers andend-users. Equally, the supply chain isresistant to change and often pursuesdevelopments only on the back ofregulatory or legislative instruction.This has led to a compromise insetting goals for materials and astifling of innovation and has madeinternational collaboration evenmore necessary. The global natureof material procurement also meansthat strategically important elementscould be subject to export control foreconomic, political or military reasons.Security of supply therefore remains akey issue for UK users.A barrier which is recognisedthroughout this report is the needto further develop our skills-base inthe sector.The increasing scarcity ofappropriately trained metallurgicalgraduates is a major concern.This is notdetailed further here as it is one of thekey findings of the IGT and reportedseparately though the People & Skillstask group.The limited availability ofskilled new entrants into the sector,may in part be compensated byensuring better transfer of knowledge,skills and technology across sectors inthe metals and materials community.A further barrier results from therestrictions on international technologyexchange resulting from export controlon contract restrictions.3.1.5 Key RecommendationsThe following recommendations are put forward as being priorities for the UK structural metals sector:1. The UK must continue to support R&D for the ‘incremental’ development and application of structural metals, whilstputting in place a research environment which can encourage ‘disruptive’ ground breaking R&D. Areas in which greatestpayback will be achieved are:i) the development of metallic systems for more aggressive operating environments (stress, temperature, corrosion, etc),ii) improved quality, efficiency and cost reduction through innovative production, processing, improved processcontrol and condition monitoring,iii) detailed understanding and mapping of full life-cycle issues. All of the above must be encouraged to includedemonstration as well as R&D.2. The UK has tremendous strengths in enabling technologies which can support the sector, including; alloy design,materials modelling, surface engineering, process development and control, condition monitoring, joining, repair,structural integrity, bespoke testing and databases. These should be further supported and developed.3. There is a need to develop a long term integrated and sustainable structure and strategy for the sector, encompassingindustry, government, RDAs, academia and funding age
Structural materials - A Science and Technology Report This report on structural materials has been produced as part of the Materials UK. It follows a series of consultations, discussions and meetings, which sought to engage with a broad cross-section of the UK structural materials community. This involved town
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