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The Centre welcomes engagement with industrial partners, and offers coordination of multi-institutional research capability and the opportunity for leverage of research support. It strongly encourages the support and assistance of industry and government-sponsored schemes in the identification of strategic design targets and the setting of research priorities. To foster increased collaborative research partnerships with industry, the Centre of Excellence offers a formal industry associates program (Program C: Linkage). A key element of this Program is to facilitate direct engagement with individual Australian and international industry partners to ensure substantive end-user input to the directions of the Centre’s research program. |
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| Program C encompasses all activities not supported by core ARC Centre funding. The Centre actively engages with various organisations to establish collaborative and/or contract research opportunities in light metals, including: |
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Asian Office of Aerospace Research and Development (AOARD) |
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Australian Institute of Nuclear Science and Engineering (AINSE) |
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Australian Research Council (ARC) |
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Central Research Grants Scheme (Deakin University) |
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Chinese Aluminium Corporation (CHALCO) |
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Cooperative Research Centre for Cast Metals Manufacturing (CRC-CAST) |
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CSIRO |
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Defense Advanced Research Projects Agency (DARPA) |
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Go8 Germany Joint Research Co-operation Scheme (DAAD) |
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Korea Institute of Materials Science (KIMS) |
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Lockheed Martin |
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Los Alamos National Laboratory (LANL) |
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Moonee Valley Council |
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Nanotechnology Victoria (Nanovic) |
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Savcor Finn Pty Ltd |
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| Asian Office of Aerospace Research and Development (AOARD) |
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Title: Comparison study of continuous SPD processes for maximum improvement of mechanical properties in aluminium aerospace alloys |
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Principal Investigator: Dr. Rimma Lapovok |
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Funding Body: AOARD, USA |
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Duration of grant: 1 January 2007 - 30 December 2007 |
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| This project studied the application of severe plastic deformation to aluminium sheet. The evaluation of severe plastic deformation techniques in comparison to conventional rolling to maximize the improvement of mechanical properties such as strength and ductility will aid in the choice of potential technology applicable to sheet processing for aircraft. An important result for aerospace applications is the ability of simple shear to induce fine-grain superplastic behaviour in a wide range of commercial alloys which promises to increase the range and decrease the cost of alloy sheet available for superplastic forming. |
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To perform the comparison study of continuous SPD techniques such as ECAE processing and asymmetrical rolling to demonstrate the potential of the above techniques with respect to conventual rolling to refine the grain size in sheet of designated representative aluminium alloy. |
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To address the benefits and draw-backs of both techniques with respect to industrial applicability. |
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To define the optimal technology for producing aluminium sheet with the maximum improvement of mechanical properties such as strength and ductility. |
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To verify the resulting improvement in biaxial formability of aluminium alloy sheet and to investigate the associated textures and mechanical properties (work hardening exponent and normal plastic anisotropy). |
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| Australian Institute of Nuclear Science and Engineering (AINSE) |
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Title: Production of multi-functional titanium alloys |
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Principal Investigator: Professor Michael Ferry |
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Funding Body: Australian Institute of Nuclear Science and Engineering |
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Duration of grant: 1 January 2008 - 31 December 2009 |
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| The aim of this project is to investigate a new route for producing Multi-Functional Titanium Alloys (MFTA) involving hot isostatic pressing (HIP) followed by equal channel angular pressing (ECAP) and to examine the optimal conditions for producing these alloys. ECAP will allow large components to be consolidated without the need for forging and hot rolling, as used by the Japanese pioneers of these alloys. Through the modification of composition or manufacturing parameters, we aim to further reduce the elastic modulus and increase the strength of MFTA for applications in the medical and aerospace industries. |
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| Australian Research Council (ARC) |
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Title: Strength Enhancement of Aluminium Extrusion Alloys via Novel Thermal Processes and Alloy Composition Control |
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Principal Investigator: Professor Jian-Feng Nie |
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Funding Body: ARC Linkage |
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Partner Organisation: Rio Tinto Alcan |
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Duration of grant: 1 January 2009 - 31 December 2012 |
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| The proposed project has the potential to establish a platform for intelligent design and development of thermal processing technologies for aluminium extrusion alloys with improved mechanical properties. Such technologies are expected to help the Australian aluminium industry to expand its international market share. |
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Title: Development of corrosion resistant aluminium alloys for potable water systems |
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Principal Investigator: Dr Nick Birbillis |
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Funding Body: ARC Linkage |
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Partner Organisation: Fortune Brands Home & Hardware Inc |
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Duration of grant: 1 January 2009 - 31 December 2012 |
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| Traditionally, water delivery occurs via copper alloy systems; however, an opportunity for aluminium-based products to enter the worldwide marketplace now exists. For this to occur, fundamental Research & Development related to durability must be accomplished. Expected outcomes of this project are targeted at the development of aluminium alloys with enhanced corrosion resistance. |
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Title: Hydro Equal Channel Angular Pressing (ECAP) – the way to industrial processing |
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Principal Investigators: Dr Rimma Lapovok & Professor Yuri Estrin |
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Funding Body: ARC Linkage |
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Partner Organisations: Warsaw University of Technology, Faculty of Materials Science and Engineering, Materials Engineers Group, Poland & Wallace Eng (Vic) Pty Ltd |
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Duration of grant: 1 January 2010 - December 2012 |
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| It is of strategic national importance to Australia to change from being an exporter of metals to becoming a purveyor of technology and high-end manufactured products. The establishment of industrially viable Hydro-ECAP technology for production of bulk ultrafine grained light alloys with superior mechanical properties will lead to a major breakthrough in the use of such materials and will help transforming Australia’s metal forming companies to future-oriented manufacturing industries. |
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Title: Enhanced mechanical properties of sheet through novel approach in asymmetric rolling |
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Principal Investigator: Dr Rimma Lapovok |
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Funding Body: ARC Linkage |
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Partner Organisations: Laboratoire de Physique et Mecanique des Materiaux, Tata Steel Limited, India |
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Duration of grant: May 2008 - May 2012 |
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| This project takes a new approach to the development of high strength, formable steels by introducing shear through a novel asymmetric rolling strategy. It is proposed that the evolution of microstructure and texture can be controlled to obtain these unique properties in new advanced high strength steels. There are a number of innovative methods planned to introduce the asymmetry into the rolling process and each will be examined for its effectiveness. The experimental work is supported through a new model development that will predict the texture as a function of the rolling parameters. This will then be validated against the laboratory data and then used to design a full scale novel commercial rolling strategy. |
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Title: The fabrication of amorphous metallic components by powder injection moulding |
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Principal Investigator: Professor Graham Schaffer |
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Funding Body: ARC Discovery |
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Duration of grant: January 2009 - December 2011 (awarded in 2008) |
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| This project has both national and international significance and addresses the National Research Priority: Frontier Technologies - Advanced Materials (light alloys). It represents new science and innovative engineering and has the potential to produce valuable new intellectual property. The project will contribute to emerging Australian expertise in both bulk metallic glasses and powder injection moulding. It will train postgraduate students in powder processing, sintering science, metallic glasses and electron microscopy. |
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Title: A 3D crystallographic framework for understanding the structure of deformed and annealed materials |
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Principal Investigator: Professor Michael Ferry |
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Funding Body: ARC Discovery |
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Duration of grant: January 2009 - December 2011 |
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| A powerful new 3D analysis technology, termed 3D-EBSD, is under intense development throughout the world. Here, a focused gallium ion beam is used for cutting parallel slices of crystalline material with a site-specific accuracy of 50 nm with each slice mapped by electron backscatter diffraction (EBSD) to generate crystallographic information at submicron resolution. However, there is an urgent need for robust computational tools for generating accurate 3D datasets where pertinent crystallographic information can be extracted. This proposal aims to develop a powerful but user-friendly computational platform for 3D-EBSD that will be used for investigating several longstanding issues concerning the nature of the deformed and annealed states in metals. |
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Title: Spark Plasma Sintering (SPS) Facility for Advanced Materials Processing |
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Principal Investigator: Professor Yi-Bing Cheng |
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Funding Body: ARC LIEF |
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Duration of grant: 1 January 2008 - 31 December 2009 |
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| The establishment of the first Spark Plasma Sintering (SPS) facility would significantly enhance Australia's capacity in manufacturing of advanced materials, especially the more sophisticated and specialized materials, which is a National Research Priority. This facility will benefit a large number of researchers and projects in Australia's premier research organisations and will also meet the needs of organisations outside the consortium. It will allow Australian researchers to remain at the leading edge of research and enhance collaborations in advanced materials nationwide. The successful outcomes of these activities will underpin the advancement in many areas of research and technology developments in the country. |
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| Central Research Grants Scheme (Deakin University) |
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Title: High strength magnesium alloys |
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Principal Investigator: Dr Nicole Stanford |
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Funding Body: Deakin University |
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Duration of grant: 1 January 2009 - 31 December 2009 |
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| The aerospace and automotive industries are interested in light weight components because weight savings can considerably reduce fuel consumption and therefore limit green house gas emissions. Magnesium alloys are very light weight, but are not particularly strong. Processing research currently underway at Deakin University has shown that the yield strength of a conventional alloy can be doubled by the application of a new one-step processing procedure. The aim of this proposal is to develop high strength magnesium alloys by the application of this newly developed process. |
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| Chinese Aluminium Corporation (CHALCO) |
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Title: Development of Al alloys for automotive applications |
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Principal Investigator: Professor Barry Muddle |
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Funding Body: Chinese Aluminium Corporation (CHALCO) |
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Duration of grant: 1 January - 31 December 2007 |
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| Two Chalco researchers received training in the preparation and characterisation of light metal alloys, which includes sample processing, microstructural characterisation and physical property measurements. Project deliverables include: |
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Completion of 12 months advanced research training of each of the designated research staff in aluminium alloy technology. |
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Enhanced collaboration between Chalco and the Centre. |
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Improved understanding of research activity in the Australian light metals arena, and the expertise, capabilities and infrastructure that are available through the Centre. |
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Joint research publications in light metals technology. |
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| Cooperative Research Centre for Cast Metals Manufacturing (CRC-CAST) |
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Title: Corrosion evaluation of experimental CAST Mg alloys |
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Principal Investigator: Dr. Nick Birbilis |
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Funding Body: CRC-CAST |
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Duration of grant: 1 July 2007 - 1 July 2009 |
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| Electrochemical corrosion testing and analysis of a range of Mg-alloys which are being developed in a previously unexplored composition range. |
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| CSIRO |
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| CSIRO has provided support for the following projects: |
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Title: Modeling of supersonic particle-laden flows |
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Principal Investigator: Mr. Shuo Li |
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Funding body: CSIRO |
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Duration of grant: 1 January 2006 - 31 December 2009 |
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| The Centre has committed to support of a research student project dedicated to modeling of supersonic particle-laden flows characteristic of the novel cold spray technology under development for application of light metal surface coatings and direct forming of powder compacts. Since the particle velocity is critical to a successful cold spray deposition, it is important to develop a realistic physical model that describes the evolution history of the powder particles and their interaction with the substrate. To date, a number of simple model problems have been solved using numerical computational techniques. The codes have been developed in C++, and have included the solution of the flow through a nozzle using the MacCormick time-stepping method. Further details are provided under the report on Project D3.2 (Cold spray). |
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| The project has attracted support from CSIRO in the form of a supplementary scholarship, operating funds and in-kind access to the research facilities at CSIRO. |
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Title: Multiscale modelling of degradation of light alloys |
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Principal Investigator: Ms. Nasia Shahzad |
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Funding body: CSIRO |
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Duration of grant: 13 March 2007 - 7 February 2011 |
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| This project focuses on developing a database of factors controlling corrosion at the micron scale. Traditionally corrosion experiments have been conducted on macro size specimens, but this problem can be resolved by miniaturizing the experiments to the micron scale using new techniques of high throughput experimentation and analysis. Essentially, thousands of micron size droplets can be placed on single specimen and variation in droplet chemistry, surface microstructure and droplet duration can be surveyed rapidly. Further as atmospheric corrosion is promoted by micron size aerosols, the data had a direct relationship to field performance. So the surface microstructure can be investigated by focusing on single microstructural feature. This experimental work will provide a crucial part of the larger program, providing critical data to develop the micron/nano scales of the model. |
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| Multi-scale modelling is a critical tool in developing new paradigm for the design and performance prediction of materials. It provides a linkage from the molecular level up to the property level and so permits the assessment of the effect of molecular changes on final properties. It will underpin existing themes such as nano-scale manufacturing, light metals, sustainable polymers and advanced materials. The development of corrosion resistant light metals is a high priority for the light metal flagship The PhD project will provide, for the first time, a mass of data at the right size range to understand the multiple factors that control the reactions of micron size aerosols with metal surfaces. This is expected to underpin the development of the multi-scale modelling as at present neither data nor conceptual understanding exists to define micron-level processes. |
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Title: The effect of hydrogen on the fine scale deformation behaviour of titanium and Ti-6-Al-4V alloys |
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Principal Investigator: Dr. Dacian Tomus |
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Funding body: Monash-CSIRO Collaborative Research Support Scheme (CRSS) |
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Duration of grant: 1 August 2007 – 31 July 2008 (awarded in 2007; funding received in 2008) |
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| The deformation behaviour of titanium, which can exist in one of two crystal structures or mixture of the two, can be affected by hydrogen content. In certain alloys hydrogen may increase ductility and decrease yield strength, and this can be exploited via thermomechanical processing of semi-finished product. Whilst the phenomenon is well known, the underlying mechanism is not well understood. This project aims to clarify the fundamental deformation behaviour of hydrogenated alloys and relate this to the microstructure, using nanoindentation combined with tensile testing performed in-situ on the powder diffraction beamline (Australian Synchrotron) and microdiffraction beamline (Advanced Light Source USA). |
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Title: Joint appointment of Professor Yuri Estrin as CSIRO-Monash Professorial Fellow |
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Principal Investigator: Professor Yuri Estrin |
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Funding body: Monash University and CSIRO |
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Duration of grant: 5 years |
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| CSIRO also funds the Australian Partnership in Light Metals Research and this is described further here. |
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| Defense Advanced Research Projects Agency (DARPA) |
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Title: Production of fully dense compact billet from Ti-alloy powder |
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Principal Investigator: Dr. Rimma Lapovok |
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Funding Body: DARPA, USA |
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Duration of grant: 1 January 2006 - 1 June 2007 |
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| The project was aimed at an investigation of the potential for cost-effective, efficient consolidation of pre-alloyed (PA) Ti-6Al-4V (HDH) powder at temperatures of 400ºC and below using Equal Channel Angular Extrusion (ECAE), with applied back pressure. The limit on processing temperature was imposed to minimise the contamination of powder and compact with gaseous constituents known to be harmful to resultant properties. An analysis of existing processing techniques, most notably those involving hot isostatic pressing (HIP), reveals that relative densities of 98-100% can only be obtained at processing temperatures in excess of 800ºC. For such methods, and temperatures below 400ºC, the relative densities achievable are typically of the order of 77%, when starting with an initial ‘tape‘-density of 63%. |
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| Go8 Germany Joint Research Co-operation Scheme (DAAD) |
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Objective: Foster research collaboration of the highest quality between Australian researchers from Go8 universities and German researchers |
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Principal Investigator: Dr Nick Birbilis |
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Funding Body: Joint initiative between Go8 and Department of Materials Science, University of Erlangen-Nuremberg |
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Duration of grant: January 2009 - December 2010 |
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| The scheme supports Dr Birbilis’ travel to Erlangen, and for collaborating German researchers to spend time at Monash University. The scope of the project is to adapt magnesium alloys for use in functional bio-resorbable implants. |
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| Specific targets are: i) Elucidating the effect of alloy microstructure and chemistry upon dissolution and biocompatibility for key magnesium alloys and ii) Developing a framework for the development of magnesium alloys to function as bio-resorbable implants. |
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| Korea Institute of Materials Science (KIMS) |
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Title: Effects of impurity elements on consolidation behaviour of commercially pure titanium powders |
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Principal Investigator: Jubeom Lim |
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Funding Body: Korea Institute of Materials Science |
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Duration of grant: 1 July 2008 - 30 June 2012 |
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| The aims of this project are: to develop a thorough understanding of the role of the major interstitial and substitutional impurity elements on the densification and sintering of commercially pure Ti powder; to quantify the effects of impurity concentrations on key processing parameters, to define tolerance limits and optimise processing conditions; and to develop quantitative computer-based models to optimise and control processing conditions. |
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| Lockheed Martin |
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Title: Aluminium alloy development for electron beam direct manufacturing |
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Principal Investigator: Ma Qian |
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Funding Body: Lockheed Martin |
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Duration of grant: November 2008 - December 2010 |
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| Electron beam direct manufacturing is an additive near-net shape forming process developed by Lockheed Martin over the last decade. The process has been successfully demonstrated on a number of complex geometry titanium components by Lockheed Martin as a replacement for titanium forgings. This new project has been formulated to develop innovative aluminium alloys that can capitalize on the advantages of electron beam direct manufacturing. |
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| Los Alamos National Laboratory (LANL) |
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Title: Strain induced nanoscale porosity in titanium |
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Principal Investigator: Dr. Rimma Lapovok |
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Funding Body: LANL, USA |
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Duration of grant: 1 January 2007 - 1 June 2008 |
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| Severe Plastic Deformation (SPD) techniques produce nanoscale structures and ultrafine-grain (UFG) sizes in a wide range of metals and alloys thus resulting in mechanical properties superior to those of conventional coarse grained materials. However, the significant improvements in basic bulk properties are not necessarily accompanied with comparable improvements in properties such as ductility or fatigue resistance that depend more sensitively on highly localized effects and the presence of microstructural inhomogeneities. |
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| Damage associated with very large plastic strain is governed by the nucleation, growth and coalescence of voids. Formation of ultrafine grains during SPD processing increases the volume fraction of grain boundaries and, therefore, the availability of void nucleation sites. The project studies formation of micro-defects under ECAP with Back-pressure using SANS, SEM and TEM techniques. |
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Characterise control samples to establish SANS baseline for undeformed titanium. |
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Severely deform six samples by ECAP at three levels of hydrostatic pressure (0 ton, 2 tons, 6 tons) at a temperature of 400OC. |
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Characterize samples by SANS to determine the presence of voids in a size range between 2 nm and 200 nm |
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Confirm the presence of macro-defects by SEM and TEM observation |
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Compare SANS results with theoretical models of void nucleation and growth. |
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| Moonee Valley Council |
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Title: Developing Aluminium nanocomposites via Severe Plastic Deformation |
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Principal Investigators: Shougie Al-Goussous & Assoc Professor Kenong Xia |
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Funding Body: Moonee Valley Council |
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Duration of grant: July 2009 - July 2010 |
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| To successfully produce aluminium nanocomposites using severe plastic deformation techniques. Al nanocomposites have the potential to produce stronger, lighter and cheaper commercial products. |
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| Nanotechnology Victoria (Nanovic) |
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Title: Antibacterial properties of TiO2 films |
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Funding Body: Nanotechnology Victoria |
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Duration of grant: January - April 2006 |
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| A short-term research project was conducted for Nanovic on the heat transfer of nanostructured surfaces and TiO2 nanostructured surfaces. Nanostructured surfaces have shown substantial improvements in heat transfer rates, which have enormous potential for industrial implementation. This work included investigation of methods for fabricating and tailoring nanostructured surfaces to enhance heat transfer, including control of porosity, testing of thermal transfer properties, and analytical surface characterisation. |
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| Damage associated with very large plastic strain is governed by the nucleation, growth and coalescence of voids. Formation of ultrafine grains during SPD processing increases the volume fraction of grain boundaries and, therefore, the availability of void nucleation sites. The project studies formation of micro-defects under ECAP with Back-pressure using SANS, SEM and TEM techniques. |
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| Savcor Finn Pty Ltd |
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Title: Characterisation and assessment of electrochemical anti-scaling technology for the alumina industry |
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Principal Investigator: Dr. Nick Birbilis |
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Funding Body: Savcor Finn Pty Ltd |
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Duration of grant: November 2008 - February 2010 |
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| This project aims to develop a comprehensive understanding of the fundamental electrochemical and scale control mechanisms associated with Savcor’s anti-scaling technology for the alumina industry. The project includes review of the current literature, electrochemical investigations of mild steel in selected alumina refining process environments, and characterisation of the resultant scale composition and morphology. |
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