Extraordinary Research Materials Science & Engineering Contents Extraordinary Research __________________________________________ 3 Royce Institute: Discovery Centre __________________________________ 4 Royce Institute: Translational Centre ________________________________ 5 Manufacture using Advanced Powder Processes ______________________ 6 Metallurgy 3D Printing for Critical Aircraft Structures ___________________________ 7 FAST-forge for Low-Cost Titanium Parts _____________________________ 8 Continuous Rotary Extrusion of Titanium Wire from Powder ____________ 9 High Entropy Alloys for Light-Weighting Vehicle Components ___________ 10 Feasibility of Vitrification of Simulant Level Nuclear Waste _____________ 11 Nuclear UK Contribution for Recovery from Nuclear Accidents ________________ 12 Cements Geopolymer Cement ___________________________________________ 13 Unravelling the Secrets of Silk ____________________________________ 14 Biomaterials Porous Materials to Support Tissue Growth ________________________ 15 Biomaterials for Nerve Reconstruction _____________________________ 16 Life Cycle Assessment of Functional Ceramics _______________________ 17 Sustainable Ceramic Processing __________________________________ 18 Functional Materials Perovskite Structured Solar Cells _________________________________ 19 Microstructural effects on the performance of high strength Nd-Fe-B magnets _____________________________________________________ 20 Composite Materials Composite Materials ___________________________________________ 21 Modelling and Modelling of Materials and Devices ________________________________ 22 Characterisation Secondary Electron Hyperspectral Imaging _________________________ 23 Cover image courtesy of Dr Giorgio Schileo 2 Extraordinary Research Extraordinary Research Materials and Manufacturing research at The the Schools of Medicine and Dentistry and the University of Sheffield spans a diverse range of more traditional engineering disciplines, allowing disciplines with core activity in the Department our researchers to exploit their understanding of of Materials Science & Engineering (MSE). With underlying physical phenomena for the public good. approximately 38 full time members of academic staff and an annual research income of ~£12M per Long term investment and support by our year, MSE was ranked in the top 5 in the UK for sponsors, both private (e.g. Rolls Royce, Boeing, research excellence and in the top ten for research GKN, Seagate, Tata Steel, Johnson Matthey, output in materials science in the Research Bentley) and public (RCUK, Innovate UK, EU), is Excellence Framework 2014. MSE was also ranked devoted to creating a better understanding of the 2nd position in Materials Technology in The Times fundamentals of material science and to resolve Good University Guide (2017), and boasts 100% challenges in a number of domains, especially the student satisfaction and 100% employability aerospace, automotive, healthcare, information achievements in 2017 surveys. technology and energy sectors. The broad and interdisciplinary nature of our We are also a major partner in the £235M Henry materials and manufacturing research is enriched Royce Institute for Advanced Materials (www. by collaborations with science departments such royce.ac.uk). In Sheffield, we will host a £30M as Chemistry and Physics & Astronomy delivering materials discovery centre in newly built facilities, the highest quality fundamental research, whilst and an £8M materials translational centre part development at higher technology readiness funded by the European Regional Development levels includes the participation of the Advanced Fund. These state of the art facilities will allow Manufacturing Research Centre with Boeing fundamental materials science to be translated and the Nuclear Advanced Manufacturing to future materials manufacturing technologies, Research Centre. Further translational research through collaboration with world leading scientists is underpinned by close collaborations between and driven by industry needs. Materials Science & Engineering 3 Royce Institute Discovery Centre The Henry Royce Institute is part of a £235m Government initiative to boost research and development in the area of advanced materials. The purpose of the Royce Discovery Centre is to take materials and processing concepts, and develop them from basic principles through analytical and experimental processes with the aim of proving the concept in terms of feasibility and applicability for industrial use. In order to achieve this, we draw on the expertise present within the Department of Materials Science and Engineering at the University of Sheffield, along with that of equipment and materials manufacturers. This allows us to understand the potential of what is possible, and investigate how this can be fully realised in an industrial setting. Particular strengths of the Department are: • Materials characterisation and testing • Microstructural modelling • Alloy development • Additive manufactured part design and optimisation Metallurgy 4 Extraordinary Research Royce Institute Translational Centre The Sheffield Royce Translational Centre has received a £4million grant from the European Regional Development Fund to help manufacturing companies in the Sheffield city region to adopt next generation technology to produce and process metal powders. The UK is already a global leader in the development of new materials for use in engineering applications, and the field is growing rapidly. The centre will work alongside the Henry Royce Institute Discovery Centre at the University’s city campus, which will be focussed on early-stage research. The translational centre will then take these research discoveries and work with companies to help apply it to their manufacturing challenges. It will house global-leading academics and engineers along with industrial-grade machines to bridge the gap between research into metal powders and applications for sectors such as aerospace, automotive, energy and medical high-value manufacturing. Facilities will include • gas atomisers • post-production powder optimisation • green part processing • vacuum induction furnace • powder densification and spheroidisation unit • laser powder bed metal 3D printer • hot isostatic press • binder powder bed metal 3D printer • metal injection moulder and metal injection furnace Part funded by the Materials Science & Engineering 5 Metallurgy Manufacture using Advanced Powder Processes MAPP is the EPSRC Future Manufacturing Hub in partners, have developed an ambitious research Manufacture using Advanced Powder Processes - programme that spans the fundamentals of a £20 million research hub, led by the University powder materials, advanced in-situ process of Sheffield. MAPP brings together leading monitoring and characterisation, and new research teams from the Universities of Sheffield, approaches to modelling and control. Researchers Leeds, Manchester and Oxford, and Imperial are working with industry partners from key UK College London, together with a founding group sectors, including aerospace and energy, and of 17 industry partners and the UK’s High Value across the full powder processing supply chain. Manufacturing Catapult. MAPP’s mission is to work with academic, MAPP’s vision is to deliver on the promise of commercial and innovation partners to drive powder-based manufacturing to provide low the research needed to solve many of the energy, low cost, and low waste high fundamental challenges limiting the development value manufacturing routes and and uptake of many powder-based processes. As products to secure UK manufacturing a recent example, Team GB used the expertise of productivity and growth. Sheffield researchers to help develop MAPP, together with their super lightweight, aerodynamic stem and handlebars for their bicycles, 3D printed at the University of Sheffield for the 2016 Rio Olympics. Metallurgy 6 Extraordinary Research 3D Printing of Critical Aircraft Structures Rolls-Royce have used additive layer The construction of the bearing marks the manufacturing (ALM) to construct a titanium first time ALM has been used to produce such front bearing housing (FBH) which is held inside a significant load bearing component, rather a Rolls-Royce Trent XWB-97 engine. Additive than the conventional processes of casting or layer manufacturing, also known as 3D printing, forging. The Department worked with Rolls- is a process by which a component is built up in Royce to develop its ALM techniques through discrete layers using a high energy source to melt a programme of testing, research and quality or fuse metal powders. assurance, building on Rolls-Royce’s experience of innovation in high value manufacturing and drawing on the department’s excellent research base in additive manufacturing. This project is a great example of how the Department of Materials Science and Engineering can work with industrial partners like Rolls Royce and the HVM Catapult Centres to translate ground-breaking early stage research to industrial practice. The fundamental research gives a strong underpinning to development activities that are closer to application providing insights into the process that increase confidence in its capabilities. This activity has facilitated a huge step forward in additive manufacture. Courtesy of Rolls-Royce Materials Science & Engineering 7 Metallurgy FAST-forge for Low-Cost Titanium Parts Researchers have developed a new concept in The technology will provide engineers