This project proposes the manufacture of low-mass, high accuracy tooling technologies, through the development of ferrous/nickel alloy (Invar) foam. Known for its low coefficient of thermal expansion, Invar is used widely for tooling, but is heavy and expensive. The key innovation proposed is the up-scaled manufacture of Invar foam, enabling low mass tooling with greatly increased dimensional stability and accuracy. This will lead to higher component dimensional tolerance and reduced expense associated with assembly, shimming and tooling heat-up. Previous attempts to use ceramic foam-based tooling have failed due to low inherent strengths, poor thermal conductivity and mismatched thermal expansions. The step change that MIONLA proposes is the use of Invar in foam-form for tooling applications, thus providing a solution to these issues. The manufacture of the foam is based on an innovative method developed within UK academia and already has IP protection.

To develop innovative manufacturing processes and materials for electrode technologies which when deployed in integrated battery and electrolyser (battolyser) systems enable low-cost green hydrogen generation.

Steel Fibre Reinforced Concrete is gaining market share because of lifetime performance improvements and the opportunity to reduce or eliminate rebar. Previous work has shown that some classes of reinforcing steel fibres can act as passive sensors which can be inspected using external electromagnetic sensing. It was demonstrated that these passive sensors indicate reversible and irreversible effects in concretes loaded and unloaded up to eventual failure. The sensing work undertaken in the project was initially based on an off-the-shelf instrument using Alternative Current Frequency Modulation (ACFM) or variant. Although successful in demonstrating the feasibility of the approach even at the low steel fibre concentrations used industrially in FRC (around 2%) it was limited both in terms of spatial resolution and penetration depth. Development of the sensor technology is now needed to optimize for the sensing application to improve so that condition of concrete structures can be monitored through life as part of asset management. Downsteam innovations are also anticipated. Easy integration of sensing capability into concrete structures will improve competitiveness in civil engineering design, build and maintainance by * confirmation of distribution of fibres at specified levels * allowing leaner design to reduce total mass of concrete in large structure with consequential reduction in embodied energy/carbon * indications of damage state after progressive or singular damage events so structures can be repaired instead of replaced * the project will help accelerate the displacement of rebar by FRC. Rebar installation is expensive both in cost and time and also suffers from a high accident rate, so the shift towards FRM will enhance competitiveness

Fibre Technology Limited has developed a unique process - Melt Overflow with Rapid Solidification Casting - to produce metallic fibres which mesh to form a non woven material - Microtex. It can be produced in a range of alloys and fibre diameters that are either technically or economically non-viable using all existing mineral fibre manufacturing processes (steel rod shaving, melt extraction or spin casting). Microtex is valued by exhaust component manufacturers as a baffle material for its superior heat and noise attenuation properties. The project will enable Fibre Technolology Ltd to fully investigate the parameters affecting fibre density and to implement a digital control system for a step change in output consistency to enable Microtex to be manufactured in volume meeting the fibre density requirements of the initial target market and opening new sector possibilities . Project partner Manchester Univerity's Materials Department will provide fibre technology and process modelling expertise and material testing will be carried out by specialist exhaust system manufacturer Vortex Limited.

Load bearing capacity and condition monitoring in large or critical concrete structures is increasingly desirable in Building Information Management Systems (BIMS) to facilitate real-time building condition monitoring and assesment and to allow competitive advantage through reduced construction cost, reduced cost of building ownership and asset life extension. This project develops a system for the non-destructive evaluation of concrete condition in steel fibre reinforced concretes.

The public description for this project has been requested but has not yet been received.

Awaiting Public Summary

Awaiting Public Summary