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Steels and Ferrous Metals
David Naylor
University Liaison Manager
Swinden Technology Centre
Corus plc
EPSRC Metallurgy Research, Present and FutureBirmingham, March 29th 2001
Metals?
• Who wants to be a Millionaire?
• Starting with the lowest, put these metals in order of annual production
Metals?
• Who wants to be a Millionaire?
• Starting with the lowest, put these metals in order of annual production
Aluminium
Steel Copper
Zinc
The future?
• Steel is vital to UK competitiveness and quality of life
• Globalisation of suppliers and users of steel
• Changing needs of customers
• The environment and sustainable development
Market Demands for Metals• Cheaper and Better Value
– Lower Life Cycle Costs– Multi-materials System Solutions
• Better Quality• Better and More Consistent Properties and Improved
Performance– Stronger, Tougher – More Resistance to Corrosion, Wear and High Temperatures– More Weldable, Formable, Machinable
• Sustainable Materials• Design for Disassembly
Compare Steel with Potatoes!
Current Innovations in Steels
• Steel Productivity in UK increased 5 fold in last 20 years – 3 times faster than UK manufacturing
• 70% of steels in cars today were developed in last 10 years
• Composition control in parts per million in 300 tonne casts
• Advanced Process Control, Sensors and Models• Systems Solutions
– Design, Materials and Fabrication Technologies
Future Research in Ferrous Metallurgy
• Lower Costs• Integrated Models from Process to Products and
Applications• Sensors and Process Control in hot, rapidly
moving environments– Temperature, Dimensions, Shape, Composition,
Microstructure, Inclusions, Defects
• Better Quality and Properties• Improved Performance under increasingly arduous
conditions and environments– Higher temperatures, pressures, more corrosive
Future Research in Ferrous Metallurgy
• New Alloys• New Shapes and Net Shapes• Added Value
– Surface Engineering – Smart Surfaces
• New Designs• New Combinations of Metals and Materials• New Fabrication Technologies• Cheap Rapid Prototyping for steel intensive
applications• Systems Solutions, combining material selection
and development, design and fabrication
Future Research in Ferrous Metallurgy
• Recyclable, Durable and Sustainable• A Multi-Disciplinary Team Approach is needed• Support the Supply Chain and Down-stream activites• Important Role for a UK Metals Research Centre
– Provide Synergy for research between industry and academia– Provide large scale multi-user facilities– Better Networking
• International research on Hydrogen Economy– Iron ore reduction and non-fossil fuel energy
• Availability of young researchers to work in these issues?