Annual Review 2020/2021 Contents 04 12 sustainsteel.ac.uk Introduction Core Research @SustainSteel to the Hub
Sustain Steel Welcome 04 Grand Challenges and Hub Overview 05 Themes 12 [email protected] Steel on the National Task Updates 16 Agenda 08 SUSTAIN Future Manufacturing Research Hub Industry Engagement 10 Swansea University Bay Campus Fabian Way Crymlyn Burrows Skewen Swansea 32 38 SA1 8EN Hub Funded Hub Activity Research
Feasibility Studies 32 Facilities 38 Early Career Events and Outreach 42 Researcher Platform 36 Awards 44 45 46 Publications Meet the Team
Publications, Articles Management Team 46 Sustainability is the biggest challenge of our generation and the and Media 45 Strategic Advisory Board 47 “ Operational Committee 48 metallurgical sciences are ready to make their contribution ” Investigators 49 - Professor Dierk Raabe - Max-Planck-Institut Researchers 50
2 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 3 Welcome Hub Overview
Dear Partners, members and future collaborators The SUSTAIN (Strategic University Steel Technology and Innovation Network) Future Manufacturing Research Hub is a £35M project funded by £10M of EPSRC funds as well as by Universities, Trade Bodies, Research and It gives us great pleasure to welcome you to the second Technology Organisations (RTO's) and Businesses over 7 years and aims to support the development of new, Annual Report for the SUSTAIN Future Manufacturing Hub, a smarter and more environmentally friendly options to ensure the future of steel manufacturing in the UK. programme based on two Grand Challenges, five Themes and 13 Tasks. The Hub was launched in April 2019 as a National The Hub is based at Swansea University, with spokes at the University of Sheffield and WMG, University of Centre of Excellence for Steel, led by Swansea University in Warwick. Our headline industrial sponsors are British Steel, Celsa Steel UK, Liberty Steel, Sheffield Forgemasters collaboration with our Spoke partners Sheffield and Warwick and Tata Steel UK. The Hub currently has academic partnerships with Cardiff University, Durham University Universities and industrial partners British Steel, Celsa Steel and University College London. UK, Liberty Steel, Sheffield Forgemasters and Tata Steel UK.
The SUSTAIN Team The Hub was launched during a period of uncertainty for UK Steel to provide a platform for novel research to deliver a net zero carbon and higher digital integration for the industry. This project focusses upon diverse areas such as Carbon Capture and Utilisation, the better use of waste products and heat energy, the development of novel sensing and analysis techniques, novel steel chemistries and processing and new digital techniques, both internally and externally within the greater supply chain.
Steel is ubiquitous and a fundamental enabler of modern life. “Steel and concrete are The intricacy of modern steelmaking and the sheer volume the working horses of the of manufacture places steel in a pivotal position to drive the circular economy – not just for steel, but for all of the modern Anthropocene. But only materials that are used with it to achieve greater product steel offers the variety functionality. Drawing upon the knowledge and esteem of the of reuse, repair and partners, the Hub continues to advance research in areas that are germane to the continuation and growth of the industry remanufacture, which is in a circular, net zero carbon future economy. Our vision is at the base of the circular to provide a profitable, sustainable industry and supply chain industrial economy. with increased GVA, employment and sovereign capability for the UK's future needs. Scientific challenges for sustainable steel include Despite the COVID-19 pandemic, over the last two years we zero-carbon production and have witnessed the growth of an incredible collaborative partnership between the steel industry and aligned academia. pure recovery technologies Working side by side to overcome the many formidable for molecules and alloys. challenges we face to enable a carbon free, truly sustainable Sustainable steel’s future future. We would like to thank each of our partners and collaborators for their continuous support to the SUSTAIN will come!” Hub and look forward to new members joining the consortium - Dr Walter Stahel - Product Life Institute to drive a successful future for UK Steel.
The SUSTAIN Team
4 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 5 SUSTAIN in Numbers
academics & new projects researchers funded by the 44 working at 6 universities 6 hub in 20/21
aligned projects secured in 20/21 >12,000 19 website page totalling views from Task 9: TEM image Task 10: Subcoal™ showing reverted austenite in pellet form in a tempered martensite £12.6m >3,500 after processing matrix in a Super 13Cr steel in additional funding unique visitors
papers & industrial engagement & articles workshop events published Task 6: Optical surface 21 10 measurements that quantitatively determine Facilities at WMG: graphite crystal orientation Alloy development have been developed young people reached through supporting >850 online outreach
attendees to project partners hub & supported Task 10: Blast furnace Tuyeres used to direct the & collaborators Task 1: Biorefinery hot air into the furnace, tubular reactor >900 events and through which milled stack for algae 20 reductants are added growth
6 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 7 Steel on the National Agenda “To ensure the continual existence of the human race where science, technology and living standards Dr Richard Curry continue to improve from generation to generation, we The UK Steel Industry, once world leading in terms of must quickly transition to a truly innovation, productivity and volume has been decimated circular economy where nothing in recent decades by new entrants to the saturated global linear economy. These new entrants, located in developing is wasted, resources are cycled nations, have access to more favourable operational costs from generation to generation with and lower national environmental targets that have applied minimal loss. increasing pressure to the European and US producers, ” reducing profit margins and potential for reinvestment and growth. As the UK moves forward post-Brexit and COVID-19, it is clear that there are vulnerabilities in many of these key be easy and will require a paradigm shift in thinking and areas that not only force dependence upon imports for our attitude - focussing upon the domestic raw materials of the own infrastructure, defence and consumables, but reduce future that we currently call ‘waste’ and making changes our ability to control quality and maximise profitability from to the way we design and manufacture products that will the high value goods we export. appear to be anathema to the current high efficiency, high productivity manufacturing processes. The global environmental crisis together with the diminishing availability and escalating prices of mined As the UK emerges from the COVID-19 pandemic, steel’s elements that are key to modern technology, living standards sheer ubiquity, production volume and potential for and renewable energy production are quickly showing that recycling, places the industry in a primary position to we can no longer exploit our ‘consume and dispose’ habits lead the UK and rest of the world in a circular economy that exemplify the linear economy to date. To ensure the revolution. The SUSTAIN project, funded by UKRI, British continual existence of the human race where science, Steel, Celsa Steel UK, Liberty Steel, Sheffield Forge Masters technology and living standards continue to improve from and Tata Steel UK together with support from the UK's generation to generation, we must quickly transition to a leading material research laboratories and Trade Bodies, truly circular economy where nothing is wasted, resources was created to lead the UK through this transition. With are cycled from generation to generation with minimal loss. focus upon the main challenges to sustainability such as This must be achieved on a foundation of carbon neutral the sequestration and reuse of waste heat and carbon energy to ensure sustainability and prevent environmental emissions, reuse of hydrocarbon wastes and end of life catastrophe. consumer goods, digital innovation, harsh environment sensor and measurement techniques and late stage Due to its size, geography and history, the UK stands in a product differentiation, SUSTAIN aims to provide a formidable position to lead the world in the transition to a national research platform to bring together the finest true circular economy that must begin with the foundation UK academics, Research and Technology Organisations industries as its nucleus. This must also include, influence (RTOs), Small and Medium Sized Enterprises (SMEs) and and shape the supply chain, higher tier manufacturing tech companies to overcome these challenges through the and tech industries to be truly circular in terms of future application of novel research to primary steel production generations of society. However, this change will not and the greater supply chain.
8 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 9 Industry Engagement Research Programme Structure
The SUSTAIN Hub is split into two Grand Challenges, five Themes and nine main Tasks. Three additional Feasibility Studies have commenced, as well as a Task 0 which aims to monitor the impact Steel is a vital material in modern society. New grades are being of the Hub as a whole. developed“ every year to reduce the ‘in use’ carbon footprint of products made from steel and supply our everyday needs in the automotive, packaging, construction and engineering sectors.
SUSTAIN is helping to bring the steel industry and academia together, to address the many challenges and opportunities for this industry. How do we de-carbonise manufacturing processes? What is the role for digital in a successful and sustainable 21st century steel industry? How do we develop the next generation of engineers and scientists to work in the industry? It’s been a pleasure to meet such passionate and capable people through SUSTAIN. I’m looking forward to the next steps in our journey together.” - Byron Tucker - Tata Steel UK
SUSTAIN is a unique opportunity for the UK-based steel companies “ to have access to a wide variety of know-how and facilities across the Universities of Sheffield, Swansea and Warwick plus networked to other academic institutions. At one time our UK steel companies were mainly one large corporate organisation with its own corporate research facilities. This has long gone, but the advantage now is access to wider academic interests, state-of-the-art research equipment and collaborative knowledge groups. Activities of interest to Liberty Steel range from management of scrap supply, steelmaking controls, digital technologies and through to design of process and products using metallurgical principles.” - Dr Simon Pike - Liberty Steel UK “Without the SUSTAIN initiative we would undoubtedly have fallen back into the trap of optimising steel properties per se instead of optimising steel properties per unit of environmental damage” - Professor Sybrand van der Zwaag - TU Delft
10 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 11 Core Research Grand Challenges and Themes
SUSTAIN Grand Challenges and Themes
The SUSTAIN project aims to address two Grand Challenges:
Carbon Neutral Iron and Steelmaking Smart Steel Processing Theme 2: Zero Waste Steelmaking Steel is ubiquitous in the modern developed world; This Grand Challenge aims to revolutionise the its low cost and the highly developed industry that steel industry through the development of steels This theme concentrates on the reuse of domestic produces it enable the standard of living we are with enhanced mechanical and physical properties, and industrial waste products within the steelmaking accustomed to. From packaging to construction, develop increased functionality and utilise the recent process. The projects here focus on the substitution transport and energy, steel plays a major part in developments in sensor technology and digital of fossil fuels with applicable landfill waste and the our daily lives without us noticing. Although the systems. Focussing on production and supply reuse of end of life ferrous materials. steelmaking process is highly efficient, for every chains, the Smart Steel Processing Grand Challenge tonne of steel produced, twice the amount of CO2 is is introducing concepts such as blockchain and The UK currently exports approximately 10 M tonnes liberated from fossil fuels to drive the process and its tracking technologies into a mature supply chain of scrap steel per year which could be recycled locally. energy requirements. The first of SUSTAIN’s Grand and customer base that will explicitly describe the The main challenge in its reuse is the management Challenges aims to develop innovative methods to manufacturing process and sourced materials on a of unknown elements inherited from a range of steel eliminate the carbon footprint of the steelmaking product by product basis giving the end customer types, and well as non-ferrous and non-metallic processes and provide a sustainable method of and government bodies full confidence in the contamination, introducing impurities. production for a carbon neutral industry which product's performance, ethical raw material sourcing, supports global needs. production and carbon footprint.
These Grand Challenges are split into five Themes:
Theme 1: Theme 3: Emissions Management and Utilisation Data Driven Innovation
This theme focusses on carbon capture and usage To be transformative, the industry will have to be of large sources of CO2 and management of other disruptive. The goal of this task is to ultimately harmful gaseous and particulate emissions. generate disruptive technologies for 21st Century supply chains and business models. The first challenge is demonstrating a robust recovery and separation process to extract CO2 from New approaches to process modelling and optimised a range of output gas streams. Then, the re-use of fast-algorithm techniques will be used to allow the captured CO2 will be investigated at laboratory real-time simulation and prediction of complex scale, before upscaling to industry. thermodynamic, kinetic and mechanical processes.
12 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 13 Core Research Grand Challenges and Themes
Progress reports by Task
As documented, the majority of the core SUSTAIN The introduction of four new Tasks (T0, T10, T11 Tasks are underway and making good progress, with and T12) has occurred over the last year, three of most PDRA positions recruited and lab work, despite which appear under the Feasibility Studies section. ongoing COVID-19 restrictions, having commenced. Although in the very early stages of development, T7 has an ongoing PhD recruitment drive thereby T0 will identify and nurture common challenges and Theme 4: delaying commencement in time for this Review. focus groups across the whole SUSTAIN activity Smart Low Energy Production landscape, including GCRA, Platform and Feasibility funds. The objective is to then evaluate the resulting This theme focusses on using smart techniques, scientific industrial impact. enhanced material properties and non-carbon sourced reactants to reduce the net carbon usage and energy required throughout the steelmaking process.
Thermal energy lost as heat throughout the steel manufacturing process is considered together with both the use of new novel materials to convert conducted and radiated heat into useful electrical energy, as is the performance and durability of existing and future refractory materials.
Theme 5: New Processes for New Products
This theme looks at the potential of using novel chemistries, processes and measurements to produce new products or improve the efficiency and consistency of existing high value steels.
One area of focus is microstructural monitoring during processing, whilst the other looks at the development of ultra-high-performance steel for improved processing efficiency, reduced process energy requirements, ultra high strength for equivalent lighter weight products and novel processes which enable late differentiation of the steel into a range of diverse products.
14 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 15 Core Research Theme 1
Carbon dioxide capture processes: The large absorber rig is currently being prepared and subsequent methanol to DME step. This will be to commence testing. There have however been carried out on a laboratory-based sub-pilot plant. The Task 1: Emissions Control delays in acquiring a new compressor power source DME unit will first be optimised using commercial with pressure drop. Additional parts to allow for Vulcanol before progressing to using our own CO2- automation of the larger rig are currently on order for derived methanol. This will allow us to streamline immediate installation when delivered. and expedite the overall process development. Start date: October 2020 Expected end date: October 2023 Pls: Professor Andrew Barron, Professor Peter Styring, Dr Enrico Andreoli Carbon dioxide thermochemical conversion: Carbon dioxide electrochemical conversion: Researchers: Dr George Dowson, Dr Waqas Hassan Tanveer As a result of the literature reviews, it has become clear The design, assembly and calibration of a bench scale that the most beneficial route to commercialisation CO2 electrolyser has been completed. Self-supported Project partners: Swansea University, University of Sheffield will be through CO2-to-DME, using renewable energy copper-based gas diffusion electrodes have been as the input (eDME). Work has begun to redesign a prepared and are undergoing tests for operational Project Abstract Industry context reactor to perform the CO2 to methanol conversion stability. The aim of Task 1 is to reduce carbon emissions from The future of the steel industry depends on the steelmaking processes by capturing and converting integration of production units where the resource the emitted carbon dioxide into high value-added use is optimised for profitability and sustainability. products. The development of this technology is Blast furnace and coke oven gases contain CO2 which, essential as the steelmaking processes in their on removal, can help deliver purified components current form will continue to generate CO2 for some including carbon monoxide and hydrogen. Whilst time. Complementary Tasks within the SUSTAIN Hub the production of steel is of core importance to are developing lower carbon technologies to further the industry, integrated steelworks could make drive the industry towards a net zero future. There additional income from by-product streams, including is a real opportunity for the overall cost of carbon the conversion of CO2 to value-added products. capture and sequestration to be offset via valuable Thermochemical and electrochemical conversion of products made from the captured CO2. CO2-derived CO2 to hydrocarbons and oxygenates (e.g. ethylene, chemicals and fuels are of particular interest to us DME) and algae biorefinery conversion of CO2 to for their added value and in some cases large market lipids and proteins are crucial to this approach. scale merit, demonstrating the potential for a future circular economy based on CO2 recycling.
Progress to Date Above: (a) Schematic representation of CO2 fed Key findings: Carbon dioxide capture materials: electrolyser setup. (b) Snapshot of the actual Above: Self-supported gas diffusion electrodes for Amine-based (triazine-based cross-linked testing station. CO2 electrolysis. (a) Photo of a copper mesh before Synthesis of CO2 capture materials completed at polyethyleneimine) materials have been successfully and after the copper foam deposition. Microscopy gram scale for testing in dynamic breakthrough images showing the general structure (b) of the synthesised, characterised and prepared at gramme system Planned Impact: microscopic structures of foams (c-e) using scale for testing in the Thermal Pressure Swing different deposition conditions. Providing the UK steel industry with designed Adsorption Unit. Experiments to characterise scalable options for carbon dioxide valorisation Lab scale CO2 electrolyser for production of the materials for dynamic CO2 breakthrough are hydrocarbons operational underway at the Research Centre for Carbon Solution (RCCS), at Heriot-Watt University in collaboration Additional Task 1 activities: Collaboration with The green hydrogen production unit has now been Protocol for preparing self-supported gas with Dr Susana Garcia with a research paper awaiting Reducing Industrial Carbon Emissions (RICE): running 12 months at Hanson UK, replacing some of diffusion electrodes for robust CO2 conversion submission once this data has been received. Carbon Dioxide Biorefinery - The biorefinery the natural gas used to process slag for aggregate. completed demonstrator is currently being installed at Vale’s Ionic liquids supported cellulose materials are Clydach Nickel Refinery. Progress has also been Pressure Swing Adsorption Unit (PSA) - A PSA unit Biorefinery demonstrator deployed at Vale currently being optimised through the use of made in assembling the bioreactor in the polytunnel. is under development for the separation of CO2 from Instrumental Gas Analysis. The data for these ionic Assembly of one section of the Perspex tubing industrial emissions and process gasses. The PSA eDME identified as the primary fuel target as a liquids will be evaluated and analysed to design housing the growing algae has been completed design has been finalised and a prototype is under ground transport alternative to the steel works enhanced materials which are capable of capturing with commissioning and testing due to commence construction. CO2 over a range of waste gas concentrations. shortly.
16 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 17 Core Research Theme 2
Progress to Date Progress has included commissioning and testing recent developments have included the development new methods for studying ultra-fast (100ms of in situ image analysis (ultra-fast digital imaging timescale), high temperature (>1000ºC) processes and fast thermal imaging). After a period where travel Task 2: Waste Reprocessing in extreme environments (oxidising/reducing) with was not possible, a visit has been made to Cardiff a focus on in situ metrology wherever possible. To University and a discussion held about initial char achieve this, ultra-fast pyrolysis has been combined samples produced from their drop tube furnace. with sophisticated time of flight GCMS to study the These chars have experienced different residence Start date: June 2020 Expected end date: June 2023 volatile fraction of fossil fuel and non-fossil fuel times at high temperature and we are studying Pls: Professor Peter Holliman, Dr Richard Thackray (e.g. non-recyclable waste, plastics, biomass and the balance between solid and volatile matter by Researchers: Dr Eurig Wyn Jones modified biomass) to begin to build a library of data combining the DTF with pyrolysis GCMS. PhD students: Fawas Ojobowale and to understand the presence and influence of Project partners: Swansea University, University of Sheffield, Tata Steel UK, N&P Recycling heteroatoms. Ex situ sample analysis has also been The Sheffield EngD project has been advertised and started to examine sample heterogeneity. Processing the start date for the successful applicant will be Project Abstract methods to both prepare samples for analysis and September 2021. Blast furnace ironmaking uses fossil fuel carbon (e.g. to co-mix materials have also been developed. More coke and coal) to provide energy and to reduce iron oxide to liquid iron. In this task, life cycle analysis will Planned Impact: be combined with experimental testing to investigate To displace fossil fuel carbon from using non-fossil fuel carbonaceous waste to displace ironmaking to reduce CO₂ emissions fossil fuel carbon within the ironmaking process. By Left: Ultra-fast using non-fossil fuel sources of carbon we aim to pyrolyser with reduce net carbon dioxide emissions and so help to pressure reactor decarbonise the overall process.
Key findings: We have shown that: Non-renewable waste can be milled to different particle sizes
Thermal analysis can study the kinetics of thermal processes for fossil fuel and non-fossil fuel carbon
Ultra-fast pyrolysis GCMS can study the sort of ultra-fast thermal processes found in a blast furnace Right: dTG data for Slow motion imaging can help to understand mixed carbon sample at different heating ultra-fast thermal processes rates
In collaboration with Cardiff University we can study the chars produced from a drop tube furnace using pyrolysis GCMS Above: Examples of non-recyclable waste
18 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 19 Core Research Theme 2
Progress to Date We have extensively engaged with industry partners We have been characterising the as-cast and (i.e. steelmakers) and beyond (metal recyclers, heat-treated steel samples using the advanced trading bodies, independent consultancy, etc) to characterisation techniques at WMG, with a focus Task 3: Scrap Utilisation identify the impurity levels for different categories of on the existence forms of impurity Cu and its steel scraps and for different steel grades. This has evolution due to heat-treatment. We have advanced been used to help design the research matrix. understanding on the co-existence of CuS and manganese silicate oxides and of CuS and (Fe,Mn)S Start date: December 2019 Expected end date: December 2022 We have carried out a critical review of the current and its evolution due to the heat treatment at 1200°C. Pls: Dr Zushu Li, Professor Claire Davis, Dr Richard Thackray metallurgical understanding about the behaviour Researchers: Dr Ishwar Kapoor of various residual elements, individually and The Sheffield PhD/EngD project associated with Project partners: WMG University of Warwick, University of Sheffield, British Steel, Celsa Steel UK, synergistically at high (>1200°C) and low temperatures the task has been advertised and the successful Liberty Steel, Sheffield Forgemasters, Tata Steel UK (<1200°C) during the casting process, with a focus on applicant will start in September 2021. local enrichment and cracking caused by the residual Project Abstract Industry context elements. This helps the steel community to increase Significantly increasing the use of the UK-generated The UK has the unique resource of abundant domestic the utilisation of steel scrap for steel production by steel scrap in steel production has become a steel scrap supply. The combination of scrap-based identifying the current constraints and opportunities. Planned Impact: strategic direction for the UK steel industry. This steel manufacturing and renewable energy presents To advance the fundamental understanding project provides fundamental understanding and a real opportunity to produce high quality steel at Based on the experimental layout and chemistry of the effects of residual elements on steel technology development to maximise the scrap low or zero carbon output. The biggest challenge designed, we used the melting and casting facilities processability and product quality and usage in manufacturing high quality steel products for the increased use of scrap is the impurities at WMG (Warwick) to make typical steel grades in consequently enable the UK steel industry to maximise scrap use in producing high quality more economically, by investigating the influence inherited from the scrap that influence the steel the laboratory, that is, low carbon free cutting steel steel economically of residual elements inherited from steel scrap on processing and service properties of steel products, (LCFCS) and low carbon steel (for comparison) while the processability and properties of typical steel particularly for automotive, aerospace, energy and the industrial samples were not available. products. It focuses on downstream processes of railway applications. The outcomes of this project steel manufacturing – casting, re-heating, hot-rolling, will provide recommendations to the steel industry to cold-rolling, annealing and mechanical properties. increase the residual tolerance of impurities in steels This will help achieve net-zero emissions and while maximising the scrap usage and reducing CO2 maintain the sustainability and profitability of the UK emissions. steel industry. Left: Co-existence of CuS with manganese silicate oxides in the as-cast low carbon steel Key findings: containing 0.4 wt%Cu Impurity and alloying elements for steel scraps and typical steel products have been identified, which is used for the design of the research matrix
Metallurgical understanding about the behaviour of various residual elements, individually and synergistically at high (>1200°C) and low temperatures (<1200°C) during the casting process, has been critically reviewed, with a focus on local enrichment and cracking caused by the residual elements
Three existence forms of copper have been found in the as-cast low carbon free Right: Cu content in (Fe, Mn)S cutting steels (LCFCS). Their evolution caused by the heat treatment at 1200°C has particle in the as-cast and heat been studied treated steel samples
The co-existence of copper and manganese silicate oxides and their evolution upon heat treatment has been investigated
20 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 21 Core Research Theme 3
For the blockchain demonstrator, initiative research Due to COVID-19, project partners were severely ideas have been proposed: blockchain will be used to affected with a large number of key staff furloughed. build a trusted distributed network of stakeholders; As a contingency, we adapted our approach by re- Semantic technologies will be used to facilitate aligning our existing SC research projects. A joint Task 4: Digital Steel Innovation Hub (DSIH) the sharing of product information and enhance project between SUSTAIN, Transforming Construction semantic interoperability. and ESRC Productivity was formed to explore the concept of SC productivity across different sectors. WMG Data Science As a result, a large-scale survey was developed. The Start date: September 2019 Expected end date: October 2023 The existing state-of-the art robotic simulator research output will be made available in the form Pls: Professor Janet Godsell, Professor Giovanni Montanna, containing one robotic hand to two robotic hands has of industry reports and a peer-reviewed academic Professor Arnold Beckmann been extended. Cooperation between two robotic journal paper. Researchers: Dr Zakiah Suhaimi, Dr Sagar Uprety, Dr Qiushi Cao hands to pick and place a bar using stated inputs has been implemented. The implementation of camera October 2020: Re-engaged with Liberty Steel as PhD students: David Ireland input-based learning algorithms for robotic hand furlough reduced. The project has been re-scoping Project partners: WMG University of Warwick, Swansea University, British Steel, Celsa Steel UK, manipulation is ongoing. and the focus shifted to steel demand from aerospace Sheffield Forgemasters, Liberty Steel, Tata Steel UK, nChain customers (e.g. Boeing) to the Bolton Air Service Supply Chain: MSc projects Centre and then to the Stocksbridge site. Detailed Project Abstract 2019/2020: Four company-based projects were research design was developed and the approach T4 aims to create a data-driven step-change Key findings: received, three are complete, one is pending. could be adopted by other steel companies. improvement in the competitiveness of UK steel A novel hybrid approach that combines 2020/2021: Currently working with Liberty Steel on supply chains (SCs). It will utilise recent developments project ‘Evaluation of inventory control management’. Relaunch of SC programme in technologies to both harness and analyse data statistical AI and symbolic AI can be proposed to facilitate and automate predictive March 2021: With the current climate, it is quite that can improve the value-added and productivity of Company case studies challenging for all companies to commit to the case maintenance in steelmaking products, processes, and UK steel industry SC. The January 2020: Organised a workshop with all studies. To give some flexibility to industrial partners, project will explore how the adoption of industrial industrial partners and agreed to have a 2-stage case a new SC programme with three-phase activities was The programmed RDF data generator can be digital technologies (IDTs) could improve steel SC study approach: relaunched. The activities include IDT assessments, productivity and sustainability. Deep reinforcement used to generate simulation data regarding Stage 1 - Liberty Steel and Forgemasters developing an IDT adoption roadmap, and case-study learning algorithms will be developed to train multiple steelmaking process Stage 2 - Tata Steel and British Steel interventions. robotic agents to collaboratively solve tasks such as object manipulation using direct input from mounted The robotic manipulation task of lifting a long/ cameras. In addition, the project will assess the heavy bar in the air can be made more sample use of a demonstrator tool in enabling real-time efficient using Hierarchical reinforcement predictive maintenance and facilitating product- learning, which breaks down task into two sub- related knowledge and data sharing among different tasks; gripping the bar, then lifting it to a target stakeholders. location Industry context T4 has been working with a number of industrial Progress to Date partners to provide them with the opportunity of Computer Science identifying rapidly promising data-driven innovations. Regarding the real-time predictive maintenance Several exploratory meetings have been organised demonstrator, several Stream Reasoning techniques to look at potential future synergies on blockchain have been studied, C-SWRL and C-SPARQL have applications (Swansea, nChain, and Celsa Steel UK) been chosen as rule language and query language to and the use of intelligent robots for automation in the perform reasoning; A RDF data generator has been Top left: existing state-of-the-art simulations wherein a steel industry (WMG and Tata Steel UK). programmed to generate RDF data streams. These single agent picks a object and places it at a target RDF data streams are treated as simulation data to be injected into knowledge models for stream Bottom left: our simulation where two agents collaborate Planned Impact: to push a long bar to target location reasoning; a high-level Industry 4.0 ontology has been To improve competitiveness of UK steel supply chains in a sustainable and value-adding way selected as a foundational ontology. This ontology Above: A novel architecture for real-time predictive will be specialised into the steelmaking domain. maintenance
22 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 23 Core Research Theme 3
Task 5: Intelligent Steelmaking
Start date: October 2020 Expected end date: December 2023 Pls: Dr Richard Thackray, Dr Michael Auinger Researchers: Dr Aurash Karimi, Dr Uchenna Kesieme Project partners: University of Sheffield
Project Abstract Industry context Many existing process models for steel production do The context to industry is to make use of existing not allow for process alignment and are too complex (old) programmes and develop new fast modelling for meaningful real-time predictive use. The primary routines for fast predictions. Depending on the interest aim of Task 5 is to take a different view on steel of the industrial partner, this can be relevant for production in its entirety by not seeking to improve optimising day-to-day process strategies or develop product qualities but by focussing on decreasing mitigation scenarios for unwanted production stops energy usage and building links over the entire or equipment breakdown. process chain. This will be achieved by development and optimisation of process level models supported Progress to Date by experimental verification, analysis of process The PDRAs have been recruited and are in place data and by benchmarking current process routes since late 2020. to quantitatively assess how efficiently industry currently uses both energy and materials. The project team is now operational and we have designed and circulated a questionnaire to the SUSTAIN industrial partners to re-evaluate their Planned Impact: modelling interests which might have changed, Delivery of coherent process level model and or become more specific during the past year. A assessments for fast and efficient optimisation literature review for fast process optimisation for of the process chain with respect to cost, energy ladle metallurgy has been finished and preliminary flow and material usage data from industry for part of the LCA analysis has been shared with the team. Above: Schematic reaction zone model for a blast furnace
Key findings: Inventory of Existing Process and Efficiency Flows Left: Schematic view of the digital process model, based on the Reaction Analytics of Process Data Zone approach Optimisation of the Building Blocks
Life Cycle Assessment to Quantify Efficiency Gains
24 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 25 Core Research Theme 4
to provide a richer information set including a novel optical technique for measuring graphite orientation (figure 2) which has been shown to Task 6: Thermal Efficiency have an effect on thermal conductivity in other systems [1]. In parallel we have conducted laboratory oxidation experiments which Start date: January 2020 Expected end date: January 2023 measured the decarbonisation kinetics of the Pls: Professor Cameron Pleydell-Pearce, Dr Karen Perkins, Dr Hollie Cockings, graphite/phenolic based binder that occur during Dr Matthew Carnie pre-heating and between use cycles. We are in the process of correlating these observations Researchers: Dr Matthew Burton, Dr Michael Dowd, Dr Ria Mitchell with characterisation methods to understand the PhD students: Geraint Howells structural sensitivities of the kinetics. Towards Project partners: Swansea University, British Steel, Celsa Steel UK, Liberty Steel, Sheffield the end of the task we will look at more complex Forgemasters, Tata Steel UK, Vesuvius PLC liquid metal/slag interactions with refractories.
Project Abstract Industry context The development of thermoelectric materials Fig 1: 3D high resolution X-Ray Computed Tomography data Task 6 aims to develop understanding of technologies The steel industry is one of the UKs largest emitters ® builds on previous work within the SPECIFIC of an Al2O3 – Carbon refractory structure segmented to that reduce heat loss through improved insulation and of waste heat; a typical steel works emits ~ 20 PJ/ IKC that has developed novel manufacturing reveal (a) all constituents and (b) the aggregate structures. maximise waste heat recovery through both thermo- yr from cooling water alone. If 25% of that heat was techniques for castable ‘near-net’ materials electric generation and heat storage materials. This recoverable at 5% efficiency, savings could be £10M/ (figure 3) [2]. Early research focussed on: 1) relies on understanding key materials and associated year (based on £0.15/kWh electricity price). Therefore the development of a tube geometry test bed processes. The project focusses primarily on two main there is commercial and environmental impetus for to test prototype generators in more complex technologies, refractory materials and heat storage reducing heat loss and recovering industrial waste geometries and 2) exploration of earth abundant, and energy generation. Initially the technologies are heat. In secondary liquid steel processing alone, each non-toxic and cost competitive systems suitable progressing in parallel with the intention to integrate 1°C improvement in thermal efficiency saves ~£2m for widespread adoption in the steel industry. The these highly complementary technologies towards per annum. Further, the temperature of steel through test bed is ready and a number of P and N type the end of the task. The project is continuously process is the most important parameter to control material options have been explored. The doping expanding its scope through complementary funding to produce high quality steel. Improved efficiency will of these systems is being optimised to improve and will soon initiate work in the area of process reduce demand on the National Grid and consumption device efficiency. In parallel we are investigating metrology and control, heat storage and the impact of fossil fuels for power generation, subsequently earth abundant half-Heusler compounds. We of emissivity on radiative heat transfer. reducing the CO2 footprint of steelmaking. intend to determine the high temperature stability of the devices and examine the potential to Progress to Date Key findings: develop self-powered temperature sensors for Fig 2: Optical surface measurements that quantitatively Key research has focussed on: 1) the development steelmaking ladles. determine graphite crystal orientation have been developed. High resolution multimodal imaging of advanced characterisation approaches for techniques have been developed that provide refractory lining materials and 2) the development of The task is now set to expand through novel insight into refractory structure thermoelectric materials through a novel ‘near-net’ complementary funding sources to examine a manufacturing process. These will be complemented wider range of potential technologies including The techniques have helped develop by studies on heat transfer efficiency at metal heat storage and radiative heat transfer efficiency surfaces and heat storage technologies. structure – property, and structure – process of metals. The work in this task has been well relationships for refractories in service complemented by the feasibility studies at The refractory characterisation has been approached Durham University and UCL and we are looking with increasing complexity. First we developed and Novel castable thermoelectric systems have to work together to progress our complementary refined acquisition and segmentation approaches been created that permit integration with technologies. complex geometries for X-Ray Computed Tomography (XCT) data of carbon bonded refractory structures. The table in Fig 3: The manufacturing method for cast near net shape Planned Impact: thermoelectric devices and schematic of how this can be figure 1 shows how these have developed to match Soon the task will expand to include heat The project aims to reduce waste heat production applied to more complex geometries. the product, whilst the images illustrate how we can storage materials and systems for steelmaking through insulation, process control and efficiency show structure segmentation. We then developed References and heat transfer efficiency in furnace and thermal energy harvesting [1] Lu. Yang et al. Materials Chemistry and Physics, Volume 257 (2021) 123702 correlative complementary microscopy techniques [2] M. Burton et al. Advanced Energy Materials, Volume 9 (2019) Issue 26 1900201
26 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 27 Core Research Theme 5
out for sensitivity to different steel samples and microstructure changes can be monitored by the EM calibration of the developed COMSOL FE model. A signal and modelling is being carried out to determine canister design has also been finalised by Dr Russ the low magnetic field permeability changes. Further Task 8: Smart Sensors for Real-Time Measurement Hall, with input from Primetals Technology Limited tests will be carried out on a different steel grade and Dr Frank Zhou and is under construction. Once (from Liberty Steel). Consideration, with University complete the array will be installed in the furnace- of Manchester, will then be needed on how to move roller table and trials will commence. from a non-deployable laboratory sensor to a sensor Start date: August 2019 Expected end date: August 2022 design suitable for use in an industrial furnace. High Pl: Professor Claire Davis High temperature annealing of two rod grades, temperature magnetic property measurements provided by British Steel, in a laboratory high for full BH behaviour are also being pursued in Researchers: Dr Frank Zhou temperature EM sensor have been performed collaboration with the University of Manchester via Project partners: WMG University of Warwick, University of Manchester, Primetals Technology to support development of microstructure – laboratory testing of a high temperature Epstein Limited, British Steel, Liberty Steel magnetic signal relationships. The results show the frame they have developed.
Project Abstract Industry context Planned Impact: Improved monitoring of steel production allows for The production of advanced high strength steel greater digitilisation and control, leading to more grades is challenging as tight process parameter EM sensor arrays for real-time in-situ monitoring, characterisation and control of steel microstructures during steel processing for a range of grades and applications efficient, less energy intensive manufacturing. control is required to achieve the complex Improved monitoring of processes is a key part to microstructures and real-time feedback is desired. sustainability, growth and modernisation for the steel Commercial sensor systems are available for cold industry. Great improvements have been made for strip steel monitoring, where sensor signals are Right: Sensor heads real-time monitoring and feedback control but several correlated to mechanical properties. Currently for the sensor array areas have been highlighted where insufficient the only commercial system for hot strip steel and COMSOL model. information is currently available requiring new microstructural monitoring is the EMspec system, The model was and improved sensing approaches. One area is produced by Primetals Technology Limited using used to optimise the sensor array design microstructural monitoring during processing and University of Manchester licensed technology, with (sensor head size and electromagnetic (EM) sensors are ideal candidates. relationships between microstructure, magnetic spacing) The project is focusing on development of new EM parameters and sensor signal developed at WMG. sensors and signal-microstructure relationships for There is a need to extend knowledge and application use in steel processing. to non-strip steel geometries and grades.
Left: High Key findings: Progress to Date temperature The new EM sensor array concept has been laboratory EM A four EM sensor head array system has modelled and optimised design determined (sensor sensors (showing been designed and built and is sensitive to sensor coils, left, head size/number/spacing). The design was carried and after high changes in steel microstructure out in collaboration with long term partners at the temperature University of Manchester (feedback and discussions potting, right) A COMSOL FE model for the sensor array with Professor Tony Peyton). Consideration of the has been developed allowing sensitivity of potential industrial applications (narrow strip mill at sensor signal to microstructure and sample Liberty Steel and wire/rod mill at British Steel) and geometry to be determined laboratory demonstration run out table was taken into Right: EM sensor account for geometry constraints. The final sensor signal (green) and array design was passed to Dr Stephen Dickinson temperature (blue) In-situ high temperature laboratory EM with time for in-situ (Organised Technology Limited) for construction sensor measurements for annealing of EM tests showing the (funded within a High Value Manufacturing Catapult rod samples has shown that pearlite change in EM signal project to upgrade the WMG furnace-roller table which is related to spheroidisation and recrystallisation containing an EMspec system). The sensor array spheroidisation of pearlite behaviour can be continuously monitored has been completed and experimental tests carried
28 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 29 Core Research Theme 5
Progress to Date A critical review has been undertaken on the control of process route has been devised that will allow Sv (austenite interfacial area per unit volume) through systematic changes in the austenite interfacial area thermomechanical processing for the selected steel per unit volume. The transformation behaviour will Task 9: Late Stage Product Definition and grades. Through experimental analysis of the cast therefore be studied as a function of Sv. This will to cast, and in-cast variations in composition of the allow a separation of the effects of composition from Integration Super 13Cr steel, a range of steel compositions have thermomechanical process conditions. been determined that will allow the effect of a) high Mn content (with otherwise target composition), b) The PhD position has been advertised but has not Start date: October 2020 Expected end date: October 2023 high Ni content (with otherwise target composition) received any eligible applications yet. The reports Pls: Professor Mark Rainforth, Professor Eric Palmiere, Dr Martin Strangwood and c) both high Mn and high Ni. These casts are of effects of pre-conditioning on austenite stability, Researchers: Dr Peng Gong being produced in-house. A thermomechanical thermodynamics and kinetics are being reviewed. Project partners: University of Sheffield, Liberty Steel, British Steel, Tata Steel UK
Project Abstract Industry context Efficiency in steel production requires relatively Efficiency in steel production requires minimal minimal changes in the upstream procedures with changes in the upstream procedures (i.e. steelmaking) product differentiation occurring during the latter with product differentiation occurring during the stages of processing. The austenite transformation latter stages of processing. Efficiency in product use to various transformation products is probably the requires design of high-quality steels with appropriate single most important factor in determining the mechanical properties and life-time durability. This final properties of most steels. The role of local activity considers both of these aspects, focusing segregation is also critical in the transformation on different steel grades and product portfolios but and subsequent heat treatment. The ability to exert utilising the strength of UK metallurgical research Right: TEM image showing greater control over the transformation gives the to provide new products and processes to position reverted austenite in a ability to have greater control of the transformation the industry at the forefront of development. This tempered martensite matrix in a Super 13Cr steel. product and subsequent final properties of the steel. project has generic applicability across all the steel This applies across all steel types, whether long manufacturers in SUSTAIN. products, strip or sections.
Key findings: The carbon content in reverted austenite is a linear function of the tempering temperature
A subsequent second temper results in redistribution of both carbon and nickel
The second temper results in austenite that is much more resistant to strain induced transformation, as a result of Planned Impact: solute redistribution Above: Carbon content in reverted austenite for The research will lead to adjustments in the hot rolling and heat treatment single and double tempered samples schedules to improve properties and deliver a more consistent product
30 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 31 Hub funded research Feasibility studies
Feasibility Studies Task 10: Drop-tube Furnace to Investigate Novel Reductants for the Decarbonisation of Ironmaking
In Summer 2020, the Hub launched its First Call for This first call was open to UK academics eligible to Feasibility Studies, initially offering funding for three receive EPSRC funding, for a maximum duration of Start date: December 2020 Expected end date: May 2021 feasibility studies to conduct novel research which six months, and a maximum value of £50,000 (80% PI: Dr Julian Steer aligned with the Hub’s two Grand Challenges: Carbon FEC). Three new Tasks (10 - 12) were funded in this Project partners: Cardiff University, Tata Steel UK Neutral Iron and Steelmaking and Smart Steel round. Processing. Research proposals had to be aligned to Project Abstract the raceway region characterised and complement the current research programme. Due to restrictions, the entire call was conducted Blast furnace Ironmaking utilises by short residence times and high Key findings: virtually, using Webinars and a Virtual Sandpit session coal injection alongside coke heating rates. Comparable sample burnouts This Call was designed to attract new partners to the held via Zoom meetings and Meeting Mojo (thanks to in the process, and this project project which may have potential to lead to further KTN for arranging the use of this platform). The Hub have been measured in some investigates the technical A range of blend compositions collaborations and future funding bids and is our was pleased with the level of engagement received Subcoal™/injection coal blends feasibility of using alternative have been tested at different primary mechanism to introduce new academic from the community in this new virtual environment reductants as a substitute residence times to establish how collaborators and develop additional research - from the submitted applications to everyone who Subcoal™ blends have similar for carbon units. The project they compare to the standard coals spokes. gave their time to support this activity, the response carbon contents to typical investigates the opportunities and and the partially burnt residues will was impressive and encouraging. issues surrounding the use of an also be tested, to compare the char injection blends alternative commercial reductant gasification reactivity. A kinetics called Subcoal™. This material is study has been run to understand Initial work suggests a mixture of paper and plastics and compare its behaviour in comparable performance of produced from residential waste combustion, gasification and different Subcoal™ deliveries which is non-recyclable and would pyrolysis conditions; this has otherwise be landfilled. Due to its been carried out to help establish Pyrolysis of Subcoal™ blends higher hydrogen content, it has the conditions for evaluation in a results in higher hydrogen potential to reduce CO2 emissions fluidised bed gasifier. and methane contents in the associated with the process by decomposition gas mixture substituting some of the mined Industry context coal and utilising biomass derived After discussion with Tata Steel paper/cardboard material. UK, it was raised that sample Top: Paper composition variability, due to the and plastic Progress to Date very mixed nature of this material, collection Incorporating a new reductant would be an important variable and into a blast furnace could lead to measure. It was also stressed processing to process stability issues with that the project output needs to serious consequences on the be in a format that production can production of Iron. So far, work relate too, so standard proximate has concentrated on investigating analysis tests will be used the incorporation of paper/plastics alongside other academic output. in the form of the commercial As a result, samples of separate Bottom: Subcoal™ product, blended with delivery batches of Subcoal™ have Subcoal™ typical coals used for blast furnace been obtained from N&P recycling. in pellet injection. Over 60 samples have form after These have been incorporated in processing been tested in a drop tube furnace, the test plan and are in the process to mimic, as closely as possible, of being evaluated.
32 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 33 Hub funded research Feasibility studies
Task 11: Ultra-High Temperature Reliable Electronics Task 12: Techno-economic Feasibility of Net-Zero Development (UHTRED) Emission Solutions for Metal Heating (THERMOS)
Start date: November 2020 Expected end date: October 2021 Start date: September 2020 Expected end date: February 2021 PI: Dr Yukun Hu Pls: Dr Alton Horsfall and Dr Andrew Gallant RA's: Xiaoyuan Cheng and Xiyao Sun PhD students: Jonathan Hammler Project partners: University College London, Warwick Manufacturing Group, Air Products and SWERIM Project partners: Durham University
Project Abstract energy consumption of the steel Key findings: Project Abstract This study will focus on the industry. Today’s best practice In the steel industry, operating temperatures above metal heating process and values for heating a tonne of Pure NH3 is hard to ignite in air, 400°C are commonplace and monitoring materials the proposed sustainable net- steel to temperature for rolling but H2 and NH3 mixture can ignite zero emission solutions, which and systems in these conditions is essential. or forging is still above 1.0 GJ/ and combust stably with 1% H2 However, semiconductor-based transistors involve hydrogen and ammonia tonne. If no disruptive innovation gas. The project will investigate are unsuitable for use in extreme temperature to the existing heating process The flame temperature of H2 and if the UK could introduce carbon- is put in place, steelmakers will environments. NH3 mix combustion increases free heating for furnaces at all its likely struggle to achieve further with H2 fraction This study will explore the use of materials, rolling mills. reduction in energy consumption designs and circuit models based around and CO2 emission. Even in the absence of a suitable microscale vacuum channel transistors. The target The project will analyse catalyst, due to moderate is to produce device and circuit designs which are combustion behaviour and scale Progress to Date capable of operating over a wide temperature formation using computational WP1: Combustion behaviour temperature, the reaction of NH3, range, from 25 to 1000°C. fluid dynamics and reaction under different environments H2 and air mainly produces N2 kinetics models. A furnace has been investigated based on and H2O Progress to Date ‘digital twin’ will be used to the burner designed provided by Identification of suitable materials for the demonstrate the proposed net- AirProducts. Both H2O and O2 promote scale manufacture of the transistors has been completed. zero emission solutions. The WP2: A mixed gas emissivity formation at high temperatures The current intention is to utilise Ir on HfO2, however work will provide new insights model has been developed (>700°C), and the excess O2 into the transition pathway of close-coupled multi-physics simulations are being which can be incorporated into should be reduced as much as reheating furnaces that might be utilised to fully optimise the work function offsets the integrated furnace model to possible in the oxyhydrogen systemic weaknesses in a green calculate mixed gas emissivity in and the effect on the transistor characteristics. combustion environment steel economy. real-time. WP3: A scale formation model Simulations of the initial lateral channel structure Key findings: has confirmed the operation of the transistor Industry context is being developed using neural- under the required operating conditions. A revised Viable, manufacturable structure identified The metal heating facility, such network algorithms, with training structure to mitigate the issues of gate control as a reheating furnace, is an and test data obtained from in the channel has been devised and are being Transistor characteristics under a range of indispensable thermal facility literature of steel scale formation. in steel production. The energy incorporated in to the model. suitable operational conditions WP4: Time needed to incorporate consumption of heating still the results and models developed accounts for about two thirds in WPs 1-3, as a digital-twin of Initial steps towards design toolkit for circuit First logic primitive circuits simulated development now completed and further of the rolling process and about the pilot-scale furnace provided 20% of the energy consumption optimisation based on the simulation data is by Swerim to investigate the Above: Transient temperature contours of underway. of steel production, which directly technical feasibility of the H2/NH3 mixture firing with air affects the production cost and proposed heating solutions.
34 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 35 Hub funded research ECR platform call
Sustainable Investment Assurance Model: SIAM
Start date: April 2021 Expected end date: November 2021 Early Career Researcher Platform Call PI: Dr Stephen Spooner Project partners: Swansea University, Celsa Steel UK, GB Recycling, BEIS In Autumn/Winter 2020 the Hub launched its first Early Career Researcher (ECR) Platform Call, with a call for proposals to conduct novel research which aligns with the Hub’s two Grand Challenges: Carbon Neutral Iron Sustainability is the theme of our generation. A example steel production reduces the CO2 emissions and Steelmaking and Smart Steel Processing. plethora of research, business activity and policy of the cement industry through slag-based lime intervention is aimed at tacking the take-make-waste substitution, which should and must be recognised The call was open to ECRs based in existing SUSTAIN Hub and Spoke institutions (Swansea University, society the linear economy has built. These initiatives formally. Once consumer relatability is achieved a University of Sheffield and University of Warwick), designed to provide ECRs with an opportunity to apply for have great intentions to reduce an activities effect precedent for inclusion in industrial and government EPSRC funding as part of this Hub. Research proposals aligned to and complementing the current research on climate impact, generate stable economics and decision making will naturally follow. programme were encouraged, especially (but not limited to) the following areas: support communities. However, an individual aspect tends to take precedent of activity drive. The project will begin by building an initial framework against measurable pillars of sustainability through The SIAM project intends to build a foundation interaction with national experts in the relevant fields industry approach to joining the wider aspects of and literature support, followed by three case studies sustainability together in a quantifiable relatable of varied application: way. Much the same as how nutrition is displayed 1. International, national, and circular manufacturing on groceries, SIAM aims to generate values on of reinforcing steel bar consumer products quantifying environmental, fiscal, 2. Cold steelmaking – a pathway to responsible competition, community and education contributions competitive UK steel manufacturing of a given product or project. This will be achieved 3. Sustainability measured project management – through extensive understanding of LCA impacts quantifying progress as a tool for improvement Microstructure and magnetic properties relationship and symbiotic supply chain and activities – for at high temperature Process design of new reduced activation ferrite Start date: May 2021 Expected end date: May 2022 martensite (RAFM) steels for nuclear fusion reactors PI: Dr Frank Zhou
Project partners: WMG University of Warwick, University of Manchester, Primetals Technologies Start date: May 2021 Expected end date: April 2022 Limited, Tata Steel UK, British Steel PI: Dr Peng Gong Electromagnetic (EM) sensors have shown enormous The project aims to study how multiple microstructure Project partners: University of Sheffield, University of Birmingham potential in non-destructive characterisation of parameters affect the magnetic properties of steels steel microstructure both offline and on-line during with varying field strength at elevated temperature Reduced activation ferritic/martensitic (RAFM) the stability during service in the temperature to even processing. EM systems are routinely deployed (in the range between room temperature and 770°C). steels are considered promising candidates for the 650°C. on-line in cold structural strip steel mills providing The magnetic properties of steels will be measured first wall and blanket of the fusion reactors. Until now, information on strength levels, and more recently the inside a furnace using high temperature Epstein the challenge for the operation of RAFM steels is the During processing, dynamic recrystallisation has EMSpec™ system has emerged for transformation frame setup. The fundamentals of how temperature short service life in these extreme service conditions. been achieved along with strain induced precipitation monitoring on-line during hot steel processing. The and microstructure parameters affect the magnetic A new type of RAFM steel has been developed in this on the grain boundaries. Compared with the current development of EM sensors for high-temperature energy terms and hence the domain structures will study with significant refinement of the grain size and RAFM steels, during ageing at 650°C for 48h after hot on-line measurement drives the need for better be studied. The outcome of this research project will high temperature stable intermetallic precipitation. rolling, the grains in the new designed RAFM steels fundamental understanding of the interrelationship enable better predictive capability for the magnetic The dynamic recrystallisation and the strain-induced have no significant coarsening, with the grain size between temperature, microstructure parameters properties of steel with different microstructures ferrite have been developed through the designed hot a factor of one times smaller. The next step of the and magnetic properties in steels. at high temperature which will make a significant rolling process to improve the mechanical properties. project will determine the conditions in which strain- impact on future intelligent on-line processing control Intermetallic precipitates, stable at high temperature, induced ferrite is formed continuously. applications. were introduced on the grain boundaries to improve
36 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 37 Facilities Steel and Metals Institute (SaMI) Swansea University
Across SUSTAIN's Hub and Spoke institutions, there is a wide variety of facilities for alloy development and Creating a 21st Century Steel and Metals Industry production, thermomechanical processing and characterisation. These include: The Steel and Metals Institute (SaMI) at Swansea University supports the steel and metals industry in the challenge to decarbonise through next generation low carbon products, reduced carbon emissions, and Swansea University creation of a circular economy. SaMI is an open access facility where research partnerships are focused on Steel and Metals Institute (SaMI) collaborative working, bringing together an extensive network of academic specialists and industrial innovators Advanced Imaging of Materials (AIM) to deliver practical innovative solutions for the steel and metals industry. SPECIFIC® IKC Lab facilities
University of Sheffield Research Capabilities Royce@Sheffield Our adaptable environment enables the Warwick Manufacturing Group, University of Warwick design and implementation of bespoke Advanced Materials and Manufacturing Centre (AMMC) research specialising in: Advanced Steel Research Centre (ASRC) Industrial decarbonisation and circular economy utilising our highly specialised facility that enables process simulations and testing under service representative conditions where extreme environments are required
Developing next generation steel and metal low carbon products through pilot scale simulation equipment for alloy development
A wide range of mechanical testing and materials characterisation techniques to support the research of the Institute and provide a service to the industry
Above: Vaccuum induction melt (VIM) for alloy development up to 50kg
Left: Swansea University PhD researcher Fawaz Ojobowale using the ultra-fast pyrolysis gas chromatography–mass spectrometer (GC-MS)
SaMI’s expert team of researchers work closely with industry to determine how best to support their research and innovation. For more information please contact: www.samiswansea.co.uk [email protected]
The open access Steel and Metals Institute (SaMI) was founded at Swansea University with Welsh Government funding
38 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 39 Alloy Research and Design Capabilities Advanced Materials Manufacturing Centre Royce@Sheffield (AMMC), WMG, University of Warwick
The University of Sheffield and the Henry Royce Institute Whether researching and designing alloys for Through Process Development: High Temperature Reactions and Kinetics: house world-class alloy research and development traditional processing methods or for newer The Centre supports full through process development This programme makes use of bespoke high expertise and unique equipment. Their facilities offer techniques such as additive manufacturing, of new and novel products, starting from trained temperature furnaces, including the ability to replicate development capabilities relevant for all metals, with Royce@Sheffield has a variety of equipment computational simulation of both thermodynamic ironmaking/steelmaking gaseous environments alloy processing from grams to tens of kilograms, ideal for developing alloys, taking them through and process topologies of a given alloy design. The while maintains addition and sampling of a system. alongside a suite of advanced characterisation laboratory scale experimental simulations of theoretical investigation can then be reinforced from Coupled with bulk laboratory experiments the team techniques allowing for a full-service approach to industrial thermomechanical processing, and for our industrially benchmarked rapid through-put suite makes use of in-situ measurements techniques alloy design and research for academia and industry. characterising the new alloys developed. which includes 1g to 10kg vacuum alloy melting, including our High-temperature Confocal Scanning Funding opportunities are available to support access followed by casting, thermomechanical processing Laser Microscope (HT-CSLM), which allows micro for target groups. Email [email protected] to discuss access. and finally surface treatments including PVD. Once visualisation of samples undergoing compression/ Alloy Development Characterisation test samples have been produced, we can interrogate tension and liquid interaction/phenomena up to Cold Crucible Arc Melting Furnace and Casting X-Ray Diffractometer a range of product performance attributes including 1,800°C. To understand how material may behave Module This new in-situ multi-functional XRD system environmental conditioning and mechanical testing at high temperatures further we also have DSC/ Used for research and prototype production, it offers allows the study of advanced materials under in- in a range of environments and temperatures. Key TGA capable of up to 1550°C and high temperature the ability to melt, cast and rapidly solidify metal alloys service and extreme conditions. equipment includes: Arc and induction melting, hot viscometry. These facilities have been applied to of nominal 200g mass using a clean, ceramic free cold Transmission Electron Microscope and cold laboratory rolling mill, PVD coater and investigations including raw material interrogation, crucible process, at temperatures exceeding 3,000°C. The TEM provides high sensitivity materials ETMT Themo-mechanical tester. simulation of novel ironmaking, direct reaction rate Vacuum Induction Melting Furnace analysis. measurements and oxidation/carburisation. Used to meet the requirements of alloys which are Hyperprobe Electron Probe Microanalyser often used in very demanding applications. There are This EPMA uses an electron beam as the excitation two furnaces for small-scale development, up-scaling source, is equipped with up to 5 channels of WDS, and research. and is capable of elemental analysis of micro Flagship Strip Caster areas with a high energy resolution. Equipment This melt spinner casts a thin ribbon of rapidly quenched Field Emission Scanning Electron Microscope amorphous material in 100g batches. It uses induction This SEM is suitable for observing fine structures Gleeble HDS-V40 melting in an inert atmosphere and a water-cooled, on the surface of a specimen. It is equipped with Confocal Scanning variable speed copper wheel to quench the metal and a Schottky electron gun and incorporates a wealth Laser Microscope generate the ribbon. of the latest technologies for high-resolution image acquisition with bias voltage applied to the Vacuum Induction specimen. Melter Thermomechanical Processing Hot and cold rolling Reversing Hot Rolling Mill Designed specifically for this facility to roll steels, titanium and nickel-based alloys from a maximum starting thickness of 80mm to a finished thickness AMMC Website of 3mm at up to 1300°C and includes a detachable run-out cooling table capable of accelerated cooling conditions. Correlative Characterisation Thermomechanical Compression The Centre houses a powerful suite of electron microscopy equipment. When combined with the co-location of This machine was designed and built to simulate the high power spoke of the national X-ray facility, which houses the firstmicro focused 750kv X-ray computed a wide range of industrial metalworking processes tomography scanner amongst other technologies, we can conduct highly specific correlative studies. An and is essential in the understanding of the example would be capturing 3D internal of porosity and inclusion fraction of thin slab cross sections, which can influence of processing on both microstructure be selectively located under SEM for composition and texture mapping, before moving on the further selected and properties. TEM to uncover aspects such as porosity ledging and complex inclusion structures.
40 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 41 Submission of Evidence to the 2070 UK commission: Online Engagement Events and Outreach Teesside Taskforce SUSTAIN's project website (www.sustainsteel.ac.uk) Does Teesside have a place for Steel? Does Steel continues to be developed and updated to feature up- have a place for Teesside? to-date research, events and staff profiles. Over the Events Organised by the Hub ACT Steel technical working group last 12 months the website has received more than SUSTAIN 19/20 Annual Review meeting Road mapping carbon emissions 12,000 page views from 3,500 unique visitors. Our On the 5th and 6th May 2020, the Hub was due to host its first annual review meeting at Swansea University’s Durham Energy Institute Joint Conference with project newsletter, as well as the LinkedIn and Twitter Bay Campus. Due to the current global situation, the team arranged for the event to go ahead using the Zoom North of England Institute of Mining and Mechanical profiles have gained subscribers and followers platform, to catch up with Task progress, convene the newly formed Strategic Advisory Board and update Engineers throughout the year, and continue to provide a great the Operational Committee on progress and develop plans going forward. There were over 50 attendees to The Transition to Net-Zero in the North of England - on platform for interactions with those both internal and the task updates, with 8 different presenters covering a plethora of topics, addressing all stages of the steel panel of 'Clean Energy and Manufacturing Solutions' external to the Hub. manufacturing process across the various plant technologies utilised in the UK sector. discussing 'Net-Zero Carbon Steelmaking'
Events Contributed to by the Hub Community Outreach and Engagement Task Engagement Highlights SUSTAIN First Call for Feasibility Studies Bessemer Masterclass and Workshops Outreach for school and community groups T1: RSC Materials Chemistry Division’s discussion In Summer 2020, the Hub launched its First Call for The Sir Henry Bessemer Lecture was held virtually for has continued online where possible. Becky, forum on “Materials chemistry for carbon capture, Feasibility Studies, conducted through Webinars and first time in 2020 allowing for more than 500 to tune SUSTAIN's Outreach Officer has been involved with utilisation and storage - improving economic viability” interactive virtual sandpit sessions. in to see Professor Dave Worsley present his lecture. the organisation of live microscopy sessions for T2: Webinar presentation to South Wales Materials Scrap Workshop Due to the uptake in attendance and international Swansea and Cardiff Science Festivals, as well as Association, 16.03.21 "It's not easy being green!" In August 2020 the Hub organised a hybrid workshop exposure, the Iron and Steel Board are considering recording videos for Swansea Science Festival, virtual Prof. Peter Holliman where we were delighted to host experts from the holding all such events virtually in the future. The school careers fairs, Get up to Speed with STEM T3: SUSTAIN Scrap Workshop presentation, 26.08.20 scrap industry to facilitate initial internal discussions Bessemer Laureate also presents a Masterclass to virtual event, British Science Week at Techniquest "Research leading to increased scrap utilisation in UK around the state of scrap in the UK, and how we can invited young engineers from the steel industry. This and STEM Ambassadors. She is also involved with steel industry" Dr Zushu Li make the most from this important resource in the year there were 50 attendees and a variety of speakers the Discover Materials working group, a national T4: Joint webinar with Liberty Steel for the Future future. hand picked to talk about the steel industry from the outreach programme involving academics and Steel Forum, 11.06.20 SUSTAIN Early Career Researcher Platform Call materials supply chain through to application by outreach officers from most of the Universities in the T6: TATA Steel and Vesuvius Refractories, “Novel In Autumn/Winter 2020 the Hub launched its first SMEs in construction and transportation. UK which offer Materials Science and Engineering Approaches to Low conductivity linings” Early Career Researcher (ECR) Platform Call. IOM3 Steel Strategy Seminars degrees. Over the last year Becky has helped organise T8: Presentation at the on-line EM sensors research SUSTAIN Inreach Seminar series On 27th October and 24th November 2020, the and deliver two digital events (Discover Materials this review meeting for projects between WMG and In March 2021 the Hub launched an internal Institute of Materials, Minerals and Mining (IOM3) Winter and Discover Materials during British Science Manchester University seminar series, to give PDRA's and PhD students hosted two steel strategy seminars sponsored by Week 2021) to introduce, and inspire school children T9: The Engineer, 25.02.21 "New steel manufacturing the opportunity to present their work and develop a the SUSTAIN Hub. The focus of these seminars was to study Materials Science and Engineering. method could lower emissions" Prof. Mark Rainforth greater understanding of the scope of the Hub and Industry 4.0, and brought together industrial and T10: WMG Webinar "Opportunities to reduce identify where collaborations between existing tasks academic specialists to present on and discuss the greenhouse house gases from Ironmaking" Dr Julian can be developed. progress and challenges the UK Steel Industry faces Steer here.
42 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 43 Awards Publications, Articles and Media
IOM3 Awards 2020: Bessemer Gold Medal - Professor Dave Worsley, Swansea Journal Paper: L. Zhou, P. Kok and C. Journal Paper: P. Styring and L. Davis, [2021]. Steel microstructure - G.R.M. Dowson, [2020]. Oxygenated Magazine Article: R. Waldram, University Magnetic permeability modelling: The Transport Fuels from Carbon Dioxide. [2020]. Supporting the development The Sir Henry Bessemer Laureate award is given by the Iron and Steel effect of ferrite grain size and phase Johnson Matthey Technology Review, of Greener, Cleaner, Smarter Steel Board (IOM3) in recognition of the outstanding services to the steel fraction. Journal of Magnetism and 65, (2), 170-179. industry in the UK. Swansea University industry made by Professor Dave Worsley. The subject of Professor Magnetic Materials, 519 (167439). DOI: 10.1595/205651321X16063027 Engineering, A Call for Engineers. 16 DOI: 10.1016/j.jmmm.2020.167439 322661 Online: online.flippingbook.com/ Worsley's lecture was coated steel products in the UK, and in India and view/572041/16-17 Mexico where the Tata Steel team are engaged with local communities to repurpose simple printing presses to make solar cells local to where Journal Paper: G.R.M. Dowson, they are needed. He presented real world examples of solar powered P. Styring and J. Cooper, [2021]. Online Article: W.M. Rainforth [2021]. Reactive Capture Using Metal New steel manufacturing method buildings and described the way in which spare power can be deployed Looping: The Effect of Oxygen. could lower emissions. The Engineer. to drive the electric vehicle revolution or provide power for communities Fig. 6. FE Modelled results of magnetic flux Faraday Discussions. Online: theengineer.co.uk/new-steel- distribution for the 0.17C steel sample (30% pearlite who may never have grid connections in the way we view them currently. in ferrite matrix): a) distribution only considering DOI: 10.1039/D1FD00001B manufacturing-method-could-lower- phase balance and b) considering phase balance and emissions grain size (20 µm grain size). (Streamline: magnetic flux density); c) representative images from 2D microstructure models, where red represents ferrite, Review Paper: I. Kapoor, C. Davis, Thornton Medal - Dr Walter Stahel, Verulam Medal and Prize blue pearlite and yellow the grain boundaries. Z. Li [2021]. Effects of residual Online Article: [2021]. From concrete Product Life Institute Professor Mark Rainforth elements during the casting process to steel, how construction makes up Presented to a speaker invited to University of Sheffield of steel production: a critical review. the 'last mile' of decarbonization. Journal Paper: P. Gong, B.P. Wynne, Ironmaking & Steelmaking. DOI: Fortune. present at either Institute conference or In recognition of distinguished contributions A.J. Knowles, A. Turk, L. Ma, 10.1080/03019233.2021.1898869 Online: fortune.com/2021/02/16/ other specially convened meeting. to ceramics including refractories. E.I.Galindo-Nava, W.M. Rainforth concrete-steel-construction-design- [2020]. Effect of ageing on the climate microstructural evolution in a new News and Views: E. Andreoli [2021]. design of maraging steels with CO2-to-ethylene electroreduction St David Awards 2020: carbon. Acta Materialia. 196, 101-121 gets a boost. Nature Catalysis. 4, 8–9 Online Article: S. Spooner [2021]. Innovation, Science and Technology award winner 2020 - DOI: 10.1016/j.actamat.2020.06.029 DOI: 10.1038/s41929-020-00568-9 Automotive recycling - can we stop Professor Dave Worsley, Swansea University downcycling our materials? ATF The St David Awards are the National awards of Wales and are Professional. Essay: R. Curry, G. Fletcher, [2020]. A Online: atfpro.co.uk/automotive- nominated by the public. The award for Innovation, Science and steely solution. Bright Blue Delivering recycling-can-we-stop-downcycling- Technology: Intended for those who have developed techniques Top 100 Women in Supply Net Zero. 144-150 our-materials or solutions that meet new requirements and who have provided Online: brightblue.org.uk/wp- Chain 2021: effective products, processes, services, technologies, or ideas content/uploads/2020/05/Final- 54 - Professor Janet Godsell, Delivering-net-zero.pdf#page=145 Webinar: P. Holliman [2021]. It's that are available to society at large. During his 30-year career at University of Warwick not easy being green. South Wales Swansea University Professor Worsley has secured more than Materials Association (SWMA) £140 million of research funding and his current EPSRC grant Online: Zoom recording portfolio of over £55 million is one of the largest in the UK and drives many partnerships within Wales.
Fig. 9. EBSD maps of Cr2Mo showing the aged microstructure evolution from (a-c) 510 °C for 5 h; (d-f) 510 °C for 8 h; (g-i) 510 °C for 16 h; (j-l) 510 °C for 48 h. Inverse pole figures (IPF) maps (a,d,g,j) show the grain orientations with respect to RD (rolling Webinar: C. Pleydell-Pearce [2021]. direction); (b,e,h,k) phase maps with blue for FCC reverted austenite and red for martensite; (c,f,i,l) Band SUSTAIN from nothing to now. Contrast maps showing the morphology of the two Sheffield Metallurgical & Engineering phases. Association (SMEA)
44 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 45 Strategic Advisory Board Key People With representatives from academia, industry and government, the purpose of the Strategic Advisory Board is to evaluate industrial and academic impact, provide technical and scientific steer, provide strategic guidance Management Team and support on the influencing of policy and assess overall progress of the Hub against its objectives. The Management Team will provide the Hub with a clear direction over its lifetime and beyond. It is comprised of representatives from each of the Spoke institutions and the Programme Manager. The purpose of the Dr Louis Brimacombe (Chair) - Consultant Management Team is to evaluate submitted proposals for academic content, resource allocation, progress Louis is a Fellow of IOM3 and a chartered Chemical Engineer. Currently working as a consultant monitoring and dealing with arising issues. and business advisor specialising in sustainable development and life cycle assessment (LCA). His leadership skills, innovative approach and vision has helped businesses to develop R&D programmes and embed life cycle thinking in their R&D and product marketing strategies. Professor Dave Worsley - Director, Swansea Mr Mike Greenall - NSG Dave is a Tata Steel sponsored Professor at the Faculty of Science and Engineering, Mike is the Chief Technology Officer of NSG, a global flat glass producer. He leads R&Dfor Swansea University and focusses on practical industrial engineering and technology the Group and is based at the NSG Technical Centre in Lancashire. The Glass industry and for sustainability. He has close ties with the UK metals and steel industries and has Steel industry face common challenges. He is looking for opportunities to exchange ideas and brought the UK’s largest volume steel producers together to tackle the environmental solutions especially in the fields of AI, emissions and recycling. and sustainability issues head on with the SUSTAIN Hub. Dr Robert Quarshie - KTN Robert currently leads all materials activities at KTN. He holds a PhD in Materials Science/ Electrochemistry (Development of High Energy Density Batteries) and a Postdoctoral Fellowship Professor Cameron Pleydell-Pearce - Deputy Director, Swansea in Steel Metallurgy. Worked in various senior management roles in the steel industry, including Cam has a long history of interfacing with industry and has significant experience of R&D, Manufacturing, Customer Technical Services, Product & market development and strategy. managing industry/academic research collaborations and relationships. Currently he is focused on consolidating and enhancing this environment locally and has a leading Professor Dierk Raabe - Max-Planck-Institut role nationally in steel research, development and innovation. Dierk Raabe studied music, metallurgy and metal physics. After his doctorate in 1992 at RWTH Aachen he worked at Carnegie Mellon University and joined Max Planck Society in 1999. His interests are in sustainable metallurgy, alloy design, computational materials science and atom probe tomography. Professor Claire Davis - Spoke Director, Warwick Dr Elizabeth Saunders - EPSRC Claire holds a Royal Academy of Engineering / Tata Steel Chair in Low Energy Steel Senior Portfolio Manager in the EPSRC manufacturing team, I manage the materials, leaders and Processing at WMG, University of Warwick. She leads the Advanced Steel Research international portfolios. I previously managed the bioenergy portfolio in the renewable resources Centre based in the Advanced Materials and Manufacturing Centre at WMG, which for clean growth team at BBSRC. My research background is in biochemistry, where my work comprises over forty researchers working on steel projects. focussed on physiological studies of industrially relevant bacteria. Mr Gareth Stace - UK Steel Gareth became Director General of UK Steel in April 2015. Gareth has acted as the voice of the sector, during the 2015-16 steel crisis and beyond. He has clearly set out to government, MPs Professor Mark Rainforth - Spoke Director, Sheffield and the media, the steps which need to be taken to give the British steel sector a chance to Mark holds a POSCO Chair in Iron and Steel Technology at the University of Sheffield. compete on a level playing field, within the global marketplace. His research interests focus on high resolution characterisation of microstructures, in particular interfaces and surfaces and cover metals, ceramics and coatings. Dr Walter Stahel - Product Life Institute Stahel is an architect by training (ETH Zürich), researcher by experience, risk manager by necessity, Professor at University of Surrey by invitation, author and keynote speaker by conviction, member of the Club of Rome and Scientific Advisory Boards to pass on to others his Dr Richard Curry - Programme Manager, Swansea circular economy experience of 45 years. Richard is the SUSTAIN Research Programme Manager, based at Swansea University, Professor Sybrand Van Der Zwaag - TU Delft and has a background in Electronic Engineering, Biomedical Sensors and Holographic Sybrand van der Zwaag has been a full professor at the TU Delft for 29 years. His research Lithography. Richard’s interests lie in circular economy, decarbonisation and Industry deals with phase transformations in chemically simple steels as well as structure-property 4.0. relationships in metals, polymers, ceramics and meta-materials. He pioneered the development of self healing materials.
46 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 47 Operational Committee Investigators
The Operational Committee members represent some of the main organisations involved in steel manufacturing in the UK. Its purpose is to review project proposals to ensure that there are opportunities for the research to be applied within the industry to confirm relevance. The SUSTAIN Management Team also sit on the Operational Committee, plus our EPSRC representative.
Dr Enrico Andreoli Dr Michael Auinger Prof. Andrew Barron Prof. Arnold Beckmann Swansea University WMG, University of Warwick Swansea University Swansea University Theme 1, T1 Theme 3, T5 Theme 1, T1 Theme 3, T4
Chris Vaughan Dr Gari Harris Chris Hagg Technical Director R&D Manager Head of External Affairs, British Steel British Steel Celsa Steel UK
Dr Matthew Carnie Prof. Claire Davis Prof. Janet Godsell Prof. Peter Holliman Swansea University WMG, University of Warwick WMG, University of Warwick Swansea University Theme 4, T6 Theme 4, T7; Theme 5, T8 Theme 3, T4 Theme 2, T2
Eoin Bailey Cathy Bell Dr Simon Pike UK Innovation Manager, Manager Research & Forensic Chief Technology Officer, Liberty Celsa Steel UK Metallurgy, Liberty Speciality Steels Steel UK; General Manager, Liberty Powder Metals Ltd
Dr Yukun Hu Dr Zushu Li Prof. Giovanni Montana Prof. Eric Palmiere University College London WMG, University of Warwick WMG, University of Warwick University of Sheffield Theme 4, T12 Theme 2, T3; Theme 4, T7 Theme 3, T4 Theme 5, T9
Prof. Jesus Talamantes-Silva Dr Laura Baker Dr Phil Clements Research, Design and Technology Head, Product Management & Director Technical, Director, Sheffield Forgemasters Development, Tata Steel UK Tata Steel UK Dr Karen Perkins Prof. Cam Pleydell-Pearce Prof. Mark Rainforth Dr Martin Strangwood Swansea University Swansea University University of Sheffield WMG, University of Warwick Theme 4, T6 Theme 4, T6 Theme 5, T9 Theme 5, T9
Dr Andrew Gallant Dr Julian Steer Durham University Cardiff University Theme 5, T11 Theme 2, T10
Byron Tucker Alan Scholes Richard Warren Head of R&D at Swansea Chief Technology Officer, Head of Policy and Prof. Peter Styring Dr Richard Thackray Dr Alton Horsfall Technology Centre, Tata Steel UK Materials Processing Institute External Affairs, UK Steel University of Sheffield University of Sheffield Durham University Theme 1, T1 Theme 2, T2,3; Theme 3, T5 Theme 5, T11
48 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 49 Researchers PhD and EngD Students
Dr Matthew Burton Dr Qiushi Cao Xiaoyuan Cheng Dr Michael Dowd Geraint Howells David Ireland Fawaz Ojobowale Jonathan Hammler Swansea University, T6 Swansea University, T4 UCL, T12 Swansea University, T6 Swansea University, T6 WMG, Warwick, T4 Swansea University, T2 Durham University, T11
Development Champions
Dr George Dowson Dr Peng Gong Dr Eurig Wyn Jones Dr Ishwar Kapoor University of Sheffield, T1 University of Sheffield, T9 Swansea University, T2 WMG, Warwick, T3 ECR project
Dr Hollie Cockings Dr Elizabeth Sackett Swansea University, T6 Swansea University
Dr Aurash Karimi Dr Uchenna Kesieme Dr Ria Mitchell Dr Stephen Spooner WMG, Warwick, T5 University of Sheffield, T5 Swansea University, T6 Swansea University, Operations Team (now University of Sheffield) ECR project
Dr Zakiah Suhaimi Xiyao Sun Dr Waqas Hassan Tanveer Dr Sagar Uprety Sarah Roberts Paula Toft Dr Becky Waldram Lydia Webber WMG, Warwick, T4 UCL, T12 Swansea University, T1 WMG, Warwick, T4 Project Officer EA to the Hub Director Outreach Officer Administrative Coordinator
Dr Frank Zhou WMG, Warwick, T8 ECR project
50 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 51 Funded by:
Academic Partners:
Industrial Partners:
Designed for SUSTAIN Steel 2021