Low temperature carbothermal reduction of alumina. Australia is the world's largest producer of alumina and bauxite; and the aluminium industry is our second largest commodity exporter. This project targets the development of fundamentals of an advanced technology for aluminium production with advantages of low energy consumption, low production costs and being more environment-friendly. This frontier technology will enhance the competitiveness of the Australian aluminium industry and contribute ....Low temperature carbothermal reduction of alumina. Australia is the world's largest producer of alumina and bauxite; and the aluminium industry is our second largest commodity exporter. This project targets the development of fundamentals of an advanced technology for aluminium production with advantages of low energy consumption, low production costs and being more environment-friendly. This frontier technology will enhance the competitiveness of the Australian aluminium industry and contribute to making an environmentally sustainable Australia. The project will also provide high quality education to final year undergraduate students. The project will contribute to the theory of metallurgical processes, particularly to the gas-solid reactions in the reduction and carburisation processes. Read moreRead less
Fundamental Investigation of metal/refractory interactions in processing of non-ferrous metals: Wettability Phenomena. This project aims to develop new understanding of interfacial phenomenon during refractory/metal reactions including the influence of novel additives on wettability leading to optimisation of refractory composition during processing of non-ferrous metals. This project will allow development of advanced refractories that will enhance corrosion resistance thereby improving refract ....Fundamental Investigation of metal/refractory interactions in processing of non-ferrous metals: Wettability Phenomena. This project aims to develop new understanding of interfacial phenomenon during refractory/metal reactions including the influence of novel additives on wettability leading to optimisation of refractory composition during processing of non-ferrous metals. This project will allow development of advanced refractories that will enhance corrosion resistance thereby improving refractory life and efficiency of metal production. This can contribute in further enhancing Australia's position as a significant producer and exporter of aluminium and associated products. The project will generate scientific data on refractory/metal interactions and establish influence of non-wetting agents in improving refractory performance against metal attack. Read moreRead less
Precision Bending of 6xxx Aluminium Extrusions. The use of aluminium in transportation applications is predicted to double over the next 10 years. The use of extruded aluminium in structural components such as space frames is a growing area, and bending is an integral and critical process in the production of such components. The aim of this project is to develop key knowledge and technology necessary for precision bending of extruded aluminium profiles. The main outcomes will be: (i) Understand ....Precision Bending of 6xxx Aluminium Extrusions. The use of aluminium in transportation applications is predicted to double over the next 10 years. The use of extruded aluminium in structural components such as space frames is a growing area, and bending is an integral and critical process in the production of such components. The aim of this project is to develop key knowledge and technology necessary for precision bending of extruded aluminium profiles. The main outcomes will be: (i) Understanding of the relationship between extrusion conditions, microstructure and bendability of structural profiles. This will enable the optimisation of the extrusion process to ensure consistent bending behaviour. (ii) Development of the rubber-pad technology for precision bending.Read moreRead less
Inter-metallic Inclusion Reduction in Continuous Metallic Coating. The ZINCALUMER coating process is a core business of BlueScope Steel. Operational and quality issues are being experienced due to inter-metallic particles in the liquid metal bath. The particles cause defects in the metal coating and agglomerate, resulting in periodic shutdowns to remove the dross. Both of these factors impact significantly on the profitability of the operation. In this project a new strategy is being investigate ....Inter-metallic Inclusion Reduction in Continuous Metallic Coating. The ZINCALUMER coating process is a core business of BlueScope Steel. Operational and quality issues are being experienced due to inter-metallic particles in the liquid metal bath. The particles cause defects in the metal coating and agglomerate, resulting in periodic shutdowns to remove the dross. Both of these factors impact significantly on the profitability of the operation. In this project a new strategy is being investigated, whereby the fluid mechanics and heat transfer mechanisms within the bath will allow inter-metallic particles to be continuously removed in the metal coating before they reach the critical size that adversely affects product quality. This will also reduce dross accumulation, thereby reducing shutdown time.Read moreRead less
The Development of High Strength Aluminium and Magnesium Alloys Using "Edge-to-edge" Matching Model. The theoretical, crystallographic "edge-to-edge" matching model for diffusion-controlled phase transformations will be applied to the practical development of improved industrial aluminium and magnesium alloys with assistance of computer simulations. The model will be used to enhance the precipitation hardening response and to identify more effective grain refiners in these light alloys. The aim ....The Development of High Strength Aluminium and Magnesium Alloys Using "Edge-to-edge" Matching Model. The theoretical, crystallographic "edge-to-edge" matching model for diffusion-controlled phase transformations will be applied to the practical development of improved industrial aluminium and magnesium alloys with assistance of computer simulations. The model will be used to enhance the precipitation hardening response and to identify more effective grain refiners in these light alloys. The aims will be the development of one high strength aluminium alloy with good ductility and one high strength magnesium alloy with good creep resistance at elevated temperatures. A computer program that will help to identify the most effective grain refiners for specific light alloys will also be produced.Read moreRead less
A study of the effects of severe plastic deformation by ECAP on the crystallographic anisotropy and the resulting microstructure-property relationships. The project will assist in improving the technology of manufacture of aluminium can body-stock, a large industry world-wide and help to keep Australian manufacture competitive with the overseas product. Because the Industry Partner has manufacturing activities in regional centres, it will also assist in strengthening regional industry.
New Approaches to Understanding Grain Boundary Chemistry. This project will provide a fundamentally better understanding of the relationship between grain boundary segregation and the recrystallisation behaviour of steel and Al alloys. This knowledge will lead to more efficient thermomechanical processing techniques, which will be of benefit to Australia's steel and light alloy industries. The experimental techniques to be developed will be the first of their kind. They have enormous potential f ....New Approaches to Understanding Grain Boundary Chemistry. This project will provide a fundamentally better understanding of the relationship between grain boundary segregation and the recrystallisation behaviour of steel and Al alloys. This knowledge will lead to more efficient thermomechanical processing techniques, which will be of benefit to Australia's steel and light alloy industries. The experimental techniques to be developed will be the first of their kind. They have enormous potential for use in future segregation studies of other alloy systems and are expected to make a major contribution to fundamental and applied research over the next few years.Read moreRead less
Thixotropic Structure Generation and Semisolid Casting of Aluminium and Magnesium Alloys. A range of aluminium and magnesium alloys will be prepared by controlled-pouring to produce structures suitable for semisolid forming. The conditions around grain nucleation and growth will be studied to ascertain the controlling factors in producing suitable microstructures. A computer model to simulate the thixotropic structure formation and define the processing parameters will be developed. Semisolid c ....Thixotropic Structure Generation and Semisolid Casting of Aluminium and Magnesium Alloys. A range of aluminium and magnesium alloys will be prepared by controlled-pouring to produce structures suitable for semisolid forming. The conditions around grain nucleation and growth will be studied to ascertain the controlling factors in producing suitable microstructures. A computer model to simulate the thixotropic structure formation and define the processing parameters will be developed. Semisolid casting using the produced feedstock will lead to extensive knowledge about the effect of different microstructures and alloys on semisolid castability. Outcomes from the project will significantly advance the scientific understanding of the thixotropic structure generation and accelerate the development of semisolid processing technology.Read moreRead less
A Novel Surface Alloying Technique to Improve the Corrosion and Wear Resistance of Magnesium Alloys. Surface mechanical attrition treatment will be used to generate nanometer-sized grains in the surface layer of engineering magnesium alloys, and therefore activate the surface of this material. Together with the use of efficient activators, the project will develop a novel low temperature surface alloying technique to significantly improve the wear and corrosion resistance of magnesium alloys wi ....A Novel Surface Alloying Technique to Improve the Corrosion and Wear Resistance of Magnesium Alloys. Surface mechanical attrition treatment will be used to generate nanometer-sized grains in the surface layer of engineering magnesium alloys, and therefore activate the surface of this material. Together with the use of efficient activators, the project will develop a novel low temperature surface alloying technique to significantly improve the wear and corrosion resistance of magnesium alloys without changing the substrate properties. Microstructural features and the wear and corrosion resistance of the ultrafine-grained surface layer will be examined. In addition, it may be possible to combine the surface alloying process with the conventional ageing process together in order to save energy.Read moreRead less
Surface Nanocrystallization and Surface Alloying of Nonferrous Alloys. The research will offer materials scientists a totally new way to undertake surface modification for nonferrous alloys. The low temperature surface alloying technique to be developed will considerably improve the surface durability, therefore increase the service life of components. Combination of the surface alloying treatment with the ageing process can save energy and lower the cost of product. This will enhance Austral ....Surface Nanocrystallization and Surface Alloying of Nonferrous Alloys. The research will offer materials scientists a totally new way to undertake surface modification for nonferrous alloys. The low temperature surface alloying technique to be developed will considerably improve the surface durability, therefore increase the service life of components. Combination of the surface alloying treatment with the ageing process can save energy and lower the cost of product. This will enhance Australia's competitive ability in international markets. The study of atomic diffusion in nanomaterials will significantly contribute to material science and increase Australian research reputation in the world. In addition, the project initiates the research on surface nanocrystallization in Australia. Read moreRead less