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
Modelling and control of electromagnetically propelled arcs in joining processes. Magnetically impelled arc butt (MIAB) joining is a non-traditional manufacturing process for tubular steel components. Parameter selection and tuning have to date been experimentally determined via exhaustive trial-and-error techniques. Therefore the full capabilities of the process have not yet been realised. The project aims to model and optimise the complex process and thus facilitate the development of new a ....Modelling and control of electromagnetically propelled arcs in joining processes. Magnetically impelled arc butt (MIAB) joining is a non-traditional manufacturing process for tubular steel components. Parameter selection and tuning have to date been experimentally determined via exhaustive trial-and-error techniques. Therefore the full capabilities of the process have not yet been realised. The project aims to model and optimise the complex process and thus facilitate the development of new and effective control strategies. It is expected that novel power source designs will emerge as an outcome of the research proposed.Read moreRead less
Model studies of the flow and thermal behaviour of non-spherical particles in fluid bed reactors. The Australian steel industry has a turnover of around $11 billion (5% of total manufacturing), being a largest manufacturing sector in Australia. Iron ore sintering and blast furnace ironmaking are two important processes in an integrated steel works. This project aims to understand and model the particle-fluid flow and thermal behaviour of non-spherical particles in the two processes, formulating ....Model studies of the flow and thermal behaviour of non-spherical particles in fluid bed reactors. The Australian steel industry has a turnover of around $11 billion (5% of total manufacturing), being a largest manufacturing sector in Australia. Iron ore sintering and blast furnace ironmaking are two important processes in an integrated steel works. This project aims to understand and model the particle-fluid flow and thermal behaviour of non-spherical particles in the two processes, formulating strategies for improving the process control and productivity and energy saving. The research outcomes (theory/model/understanding) are useful to fluid bed reactors which are widely used in mineral/metallurgical/chemical industries. Their application can improve the competitiveness of the steel and other industries in Australia.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
New Generation Pipeline and Q&T Plate Steels. If successful, the progressive reformulation of the alloy design of a new family of steels would enhance their properties, greatly reduce the complexity of manufacture, ensure more efficient steelmaking production practices and enable the full capacity of the domestic pipe mills and plate manufacturing facilities to be realised. This innovative and new approach opens up opportunities for market growth and export potential in areas of fundamental impo ....New Generation Pipeline and Q&T Plate Steels. If successful, the progressive reformulation of the alloy design of a new family of steels would enhance their properties, greatly reduce the complexity of manufacture, ensure more efficient steelmaking production practices and enable the full capacity of the domestic pipe mills and plate manufacturing facilities to be realised. This innovative and new approach opens up opportunities for market growth and export potential in areas of fundamental importance to Australia's infrastructure and mining industries and defence capability. Implementation of this newly developed technology would, for the first time, create export market opportunities for Australian pipe manufacturers.
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Understanding and minimising oxidation during hot rolling and metal coating of steel strip. Steel production is one of the few manufacturing industries in which Australia is internationally competitive. Annual steel exports generate about two billion dollars in national income. Substantial value is added to raw steel by hot rolling it into sheet and coating with zincalume and paint. The market for these products is intensely competitive, and continued success is critically dependent on produc ....Understanding and minimising oxidation during hot rolling and metal coating of steel strip. Steel production is one of the few manufacturing industries in which Australia is internationally competitive. Annual steel exports generate about two billion dollars in national income. Substantial value is added to raw steel by hot rolling it into sheet and coating with zincalume and paint. The market for these products is intensely competitive, and continued success is critically dependent on productivity and quality. This project will assist BlueScope Steel in understanding and controlling millscale development on hot rolled products, and avoiding scale defects in zincalume coating.Read moreRead less
Experimental and numerical studies of the packing and piling of coal. This project is oriented to the coal and steel industries, which are important to Australia. In fact, the coal industry creates a significant employment and produces 80% of electricity in Australia. Australia is also the world's biggest coal exporter. This project will develop methods to control the packing and piling processes of coal, which are of fundamental importance to many granular processes. The benefits from the proje ....Experimental and numerical studies of the packing and piling of coal. This project is oriented to the coal and steel industries, which are important to Australia. In fact, the coal industry creates a significant employment and produces 80% of electricity in Australia. Australia is also the world's biggest coal exporter. This project will develop methods to control the packing and piling processes of coal, which are of fundamental importance to many granular processes. The benefits from the project include improvements in productivity, coke quality and fuel efficiency, which will lead reduced energy consumption and pollution emission and thereby improve the competitiveness of Australia's coal and steel industries. Read moreRead less
Free Surface Instability and Gas Entrainment during Blast Furnace Drainage. Iron and Steelmaking operations have underpinned Australia's industry base for many years. To remain competitive in a global market BHP has undertaken considerable research and development to constantly improve process performance. An area of on-going concern is the unexpected release of gas during Blast Furnace drainage resulting in hazardous conditions for the operators and overall loss of production. This project aims ....Free Surface Instability and Gas Entrainment during Blast Furnace Drainage. Iron and Steelmaking operations have underpinned Australia's industry base for many years. To remain competitive in a global market BHP has undertaken considerable research and development to constantly improve process performance. An area of on-going concern is the unexpected release of gas during Blast Furnace drainage resulting in hazardous conditions for the operators and overall loss of production. This project aims to identify the causes of gas release and to devise operational strategies and design modifications to prevent this occurrence. Once implemented the outcomes of the research will be a more stable operation leading to increased production and less environmental emissions.Read moreRead less
Slag Entrainment and Dispersion in Continuous Slab Casting. Australia's steel industry employs 75,000 people and has an annual turnover in excess of $21 billion. However, it produces less than 8 million tonnes of steel per annum which is approximately 7 percent of the world's production. Australia does not have the economies of scale and to be competitive, must invest heavily in new technology and have best workplace practices to generate products that are superior to low cost competitors. This ....Slag Entrainment and Dispersion in Continuous Slab Casting. Australia's steel industry employs 75,000 people and has an annual turnover in excess of $21 billion. However, it produces less than 8 million tonnes of steel per annum which is approximately 7 percent of the world's production. Australia does not have the economies of scale and to be competitive, must invest heavily in new technology and have best workplace practices to generate products that are superior to low cost competitors. This project is focussed on improving product quality through invention of new equipment which also overcomes current operational practices and creates a safer working environment. Read moreRead less
Experimental and numerical studies of the packing of alumina powders. This project is to investigate the packing of alumina powders at both microscopic and macroscopic levels by means of physical and numerical experiments, aiming to develop a comprehensive understanding of the underlying physics and computer models for predicting the packing properties under conditions corresponding to different operations in alumina refining and smelting processes. It will generate an effective method to solve ....Experimental and numerical studies of the packing of alumina powders. This project is to investigate the packing of alumina powders at both microscopic and macroscopic levels by means of physical and numerical experiments, aiming to develop a comprehensive understanding of the underlying physics and computer models for predicting the packing properties under conditions corresponding to different operations in alumina refining and smelting processes. It will generate an effective method to solve the complex packing problems for process and/or property control in alumina/aluminium industry.Read moreRead less