Understanding the role of nanoparticles in water based lubrication. This project seeks to understand the role of nanoparticles in the lubrication of hot strip rolling and then to develop novel nano-additive water-based lubricants to solve a long-standing issue for the steel-making industry. Lubrication significantly affects the surface quality of hot-rolled strips, roll wear and energy consumption in the steel-making industry. Currently, oil-based lubricants are used. However, their lubricant ef ....Understanding the role of nanoparticles in water based lubrication. This project seeks to understand the role of nanoparticles in the lubrication of hot strip rolling and then to develop novel nano-additive water-based lubricants to solve a long-standing issue for the steel-making industry. Lubrication significantly affects the surface quality of hot-rolled strips, roll wear and energy consumption in the steel-making industry. Currently, oil-based lubricants are used. However, their lubricant effect is considerably reduced by the use of high pressure cooling water, and the waste discharge is of environmental concern. Successful outcomes for the project are expected to improve product quality and reduce resource use.Read moreRead less
Non-destructive characterisation of residual stresses for the silicon-on-sapphire technology. Every sapphire wafer for the fabrication of integrated circuits using the silicon-on-sapphire technology is worth more than a thousand dollars, and the cost grows exponentially with successive processing of circuitry. Early detection and prevention of wafer failure is therefore an economic and quality necessity. The fast, non-destructive method to be developed by the proposed research will enable semic ....Non-destructive characterisation of residual stresses for the silicon-on-sapphire technology. Every sapphire wafer for the fabrication of integrated circuits using the silicon-on-sapphire technology is worth more than a thousand dollars, and the cost grows exponentially with successive processing of circuitry. Early detection and prevention of wafer failure is therefore an economic and quality necessity. The fast, non-destructive method to be developed by the proposed research will enable semiconductor electronics manufacturers to achieve a cost-effective fabrication of integrated circuits by detecting damages in wafers at the very early stage of production.Read moreRead less
A new abrasive waterjet milling technology and process models for fabricating energy-efficient electrical machines from amorphous magnetic metal laminations. As the most energy-efficient core material for electrical machines, amorphous magnetic metal (AMM) can save more than 36% of the energy wasted by ordinary electrical motors. Since electrical motors consume about 70% of all the electricity generated, if all electrical motors in Australia use AMM as the core material, an annual energy saving ....A new abrasive waterjet milling technology and process models for fabricating energy-efficient electrical machines from amorphous magnetic metal laminations. As the most energy-efficient core material for electrical machines, amorphous magnetic metal (AMM) can save more than 36% of the energy wasted by ordinary electrical motors. Since electrical motors consume about 70% of all the electricity generated, if all electrical motors in Australia use AMM as the core material, an annual energy saving worth approximately $4 billion and an annual reduction of 16 million tonnes of greenhouse gas emission in Australia are expected based on the predicted electricity consumption in 2010. This project will develop a new technology for fabricating larger electrical machines from AMM laminations. It targets the national research priorities in Frontier Technologies and An Environmentally Sustainable Australia.Read moreRead less
Flame-Retarding and Mechanically Resilient Elastomer Composites. This project will develop a new generation of flame-retarding and mechanically resilient elastomer composites by taking advantage of nanoscale effect and synergy. The outcomes will be two types of flame-retarding additive pellets and their elastomer composites; these pellets also suit other polymers such as thermoplastics. The elastomer composites are expected to have excellent flame retardancy, mechanical properties, and fatigue p ....Flame-Retarding and Mechanically Resilient Elastomer Composites. This project will develop a new generation of flame-retarding and mechanically resilient elastomer composites by taking advantage of nanoscale effect and synergy. The outcomes will be two types of flame-retarding additive pellets and their elastomer composites; these pellets also suit other polymers such as thermoplastics. The elastomer composites are expected to have excellent flame retardancy, mechanical properties, and fatigue performance, to meet the demands from industrial partners. The project will provide a platform for elastomer manufacturing industry to develop flame-retarding, high-performance products for domestic applications and for export. Read moreRead less
Development of High Performance Mechanical Sorting of Plastics for Recycling. This research program aims to develop and test a range of high performance, mechanical in-process plastics sorting technologies in conjunction with Australia's lead recycling company. Currently, recycling techniques result in an insufficient purity and quality level, thus limiting the extent of recycling and opportunity for end product applications. Increasing the purity of recycled plastics and economics of recyclin ....Development of High Performance Mechanical Sorting of Plastics for Recycling. This research program aims to develop and test a range of high performance, mechanical in-process plastics sorting technologies in conjunction with Australia's lead recycling company. Currently, recycling techniques result in an insufficient purity and quality level, thus limiting the extent of recycling and opportunity for end product applications. Increasing the purity of recycled plastics and economics of recycling, without compromising throughput levels, will result in an increase in recycling rates and the range of applications of recycled plastics.Read moreRead less
Value Adding to Australian Cashmere Fleece. This project will lead to major technical advance in the processing of both cashmere fibres and cashmere guard hair. Reducing the level of breakage in fine cashmere fibres will add significant premium to the price of cashmere fibres and products. In addition, the large amount of coarse guard hair removed from cashmere dehairing process will be converted into quality fine powders, which will add significant value to an otherwise 'waste' product. This pr ....Value Adding to Australian Cashmere Fleece. This project will lead to major technical advance in the processing of both cashmere fibres and cashmere guard hair. Reducing the level of breakage in fine cashmere fibres will add significant premium to the price of cashmere fibres and products. In addition, the large amount of coarse guard hair removed from cashmere dehairing process will be converted into quality fine powders, which will add significant value to an otherwise 'waste' product. This project will benefit the entire animal fibre industry, particularly the rare animal fibre industry.Read moreRead less
Process models and control strategies for abrasive waterjet precision cutting of amorphous magnetic metal parts for energy efficient electrical machines. Amorphous magnetic metal (AMM) is the most energy-efficient material for electrical machines and can save more than 36% of the energy wasted by an electrical motor using an ordinary core material. Since electrical motors consume about 70% of all the electricity generated, energy saving of approximately $900 million annually in electricity bills ....Process models and control strategies for abrasive waterjet precision cutting of amorphous magnetic metal parts for energy efficient electrical machines. Amorphous magnetic metal (AMM) is the most energy-efficient material for electrical machines and can save more than 36% of the energy wasted by an electrical motor using an ordinary core material. Since electrical motors consume about 70% of all the electricity generated, energy saving of approximately $900 million annually in electricity bills, and an annual reduction of 2.5 million tonnes of greenhouse gas emissions in Australia are expected. This project will develop a unique technology able to cut AMM to the required quality and productivity. It targets the national research priorities in Frontier Technologies and An Environmentally Sustainable Australia. Read moreRead less
Scaling manufacture of three-dimensional microstructures for the medical devices industry. Scaling manufacture of three-dimensional microstructures for the medical devices industry. This project aims to transform microscale three-dimensional prototyping into a cheap high volume manufacturing process through a novel soft embossing process. Although three-dimensional printing has been hailed as a disruptive technology, because it can print complex shapes directly from drawings, it is too slow at m ....Scaling manufacture of three-dimensional microstructures for the medical devices industry. Scaling manufacture of three-dimensional microstructures for the medical devices industry. This project aims to transform microscale three-dimensional prototyping into a cheap high volume manufacturing process through a novel soft embossing process. Although three-dimensional printing has been hailed as a disruptive technology, because it can print complex shapes directly from drawings, it is too slow at microscale for high volume manufacture. This research will develop microdevices for painless collection of blood, its analysis, and drug delivery. Cost-effective manufacture of these microdevices is expected to tap into the large medical devices industry, leading to establishing new businesses in the point-of-care and drug delivery markets.Read moreRead less
Hydro Equal Channel Angular Pressing (ECAP) - the way to industrial processing. Australia has rich resources in aluminium, titanium and magnesium. 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. To compete in the global market, Australia needs to be in a leading position in production of light alloy components for automotive, aerospace, electronic, and bio-medical applications. ....Hydro Equal Channel Angular Pressing (ECAP) - the way to industrial processing. Australia has rich resources in aluminium, titanium and magnesium. 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. To compete in the global market, Australia needs to be in a leading position in production of light alloy components for automotive, aerospace, electronic, and bio-medical applications. 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.Read moreRead less
Sustainability Cockpit: an integrated tool for assessment and improvement of sustainability in manufacturing. This project aims to understand the relation between the traditional business indicators, such as cost, and the environmental indicators, such as carbon footprint. The outcome of this project will be an integrated tool which will allow manufacturers to assess and improve their environmental footprint in a cost effective manner.