Net shape parts of typically intricate and complex shape obtained by powder metallurgy (PM) are employed in several key mass industry sectors, especially automotive, aerospace and medical. Their use is growing rapidly in preference to conventional casting because the process produces parts in the precise final shape required with little or no machining requirement combined with fine grained (nano-micro scale), homogeneous microstructures of enhanced strength. However there is a lack of production quality control as little in-line inspection is performed. End-of-line inspection, not often performed, leads to scrapping of 6-8% of components yet fails to detect micro sized defects, which can grow in service to produce major in service failures and recalls. THE PROJECT VISION is an in-line quality control system (QUALINET) using 3D microfocus x ray imaging (µXCT) with AUTOMATION INNOVATIONS (A) Detection and characterization of volume and surface micro-scale defects at the pre and post sintering stages. (B) Decision making: (i) component acceptance or (ii) send for recycling or (iii) send with a prescription for defect healing treatment. QUALINET will eliminate waste, increasing line production, reducing energy consumption and carbon emissions, all by 8%. The benefit will be optimal for state of the art PM component lines including additive manufacturing by laser deposition, nano-powders and injection moulding. Estimated ROI comprising the profits of the partners, licensees and the savings in reduced waste from the PM systems on which the QUALINET sold system would be installed are 111:1 in the EEA and 35:1 over the first 5 years of commercialisation. Global acceptance of the net technolgy could save £340mpa.

There is an ongoing requirement to develop new brake disc solutions for rail vehicles which offer improved frictional performance, longer service life and lower overall mass without hugely increasing the overall cost. This feasibility study will examine the potential of using the laser cladding process to apply novel advanced ceramic particle reinforced metal matrix composite material as an improved frictional wear surface to discs. It will also examine the feasibility of remanufacturing worn discs at the end of their service lifetime and refurbishing them to a standard to allow their re-insertion back into service, coupled with the addition of the improved performance friction cladding. The process will be demonstrated on full size worn discs and a full cost benefit analysis conducted to assess the commercial viability of this approach, which is expected to contribute significant reductions in operational costs and carbon footprint.

The utilisation of biomass fuels, fired in dedicated boiler plants or co-fired with fossil fuels, provides a method of generating continuous renewable energy and, combined with CO2 capture and storage, provides one of the means of reducing CO2 levels in the atmosphere, whilst helping to ensure security of power supply. However, biomass combustion products can be challenging, particularly in terms of the risks of excessive rates of metal loss of high temperature boiler components due to fireside corrosion. It is considered that the development and use of effective corrosion resistant coatings would enable power plant to operate at higher temperature & efficiencies and utilise lower grade fuels. The proposed project is intended to build on the knowledge gained from the TSB co-funded ASPECT project, which was concerned with the development and evaluation of coating materials for advanced fossil fuel plants, and to address issues related to biomass derived flue gas chemistries.

The lifetime of any rail track section is limited by the issues of surface wear and rolling contact fatigue (RCF). These result from the successive interactions between train wheels and the rail head, which cause cumulative damage to the rail head surface. This leads to crack initiation and growth via RCF, which can ultimately lead to rail failure. Crack growth is currently mitigated by periodic grinding of the rail head which, although effective, also significantly shortens the life of the rail. Although more wear and RCF resistant materials are available, it would be difficult or prohibitively expensive to produce entire rail sections from them. The proposed project uses laser cladding to selectively deposit higher performance materials selectively on to the surface of standard grade rail steel, offering the possibility of tailoring the rail head surface to improve wear/RCF resistance. This technology may also be able to repair rail defects and to refurbish removed worn rails for re-introduction back into service.