PRESENTATIONS

Neha Agarwal | Dublin City University

Co-authors: Karthikeyan Tamil Selvam, Muhannad Ahmed Ibeidi, Dermot Brabazon (Dublin City University)

Session Six: Wednesday 19 July, 1130-1300

EFFECTS OF PRINTING PARAMETERS ON PHASE TRANSFORMATION TEMPERATURE AND MECHANICAL PROPERTIES OF NITINOL FOR MEDICAL DEVICE MANUFACTURING USING LASER POWDER BED FUSION

Medical devices are often of complex geometries, with precise dimensional features with

simple single-step manufacturing technique. Additive manufacturing meets these requirements

and minimises the amount of material used. This study focuses on examining the effect of

changing the printing parameters levels such as laser beam input power and scanning speed, on

the phase transformation temperature and mechanical properties of the produced AM parts

using laser powder bed fusion technique. The investigated phase transformation temperatures

were characterised by using the differential scanning calorimetry (DSC) and mechanical

properties using Vickers hardness and ultimate tensile testing.

Siti Nurlisa Binti Ahmad | University of Sheffield

Co-author: Dr. Richard Thackray (University of Sheffield)

Session One: Tuesday 18 July, 0900-1100

ENVIRONMENTAL IMPACTS OF ALTERNATIVE MATERIALS IN IRONMAKING

This study evaluates the feasibility of alternative fuels such as subcoal, charcoal, and wood pellets to replace traditional coal fuel in steelmaking to reduce global CO2 emissions. The study employs a risk assessment methodology to evaluate each fuel’s efficiency, environmental impacts, and fuel economics. It identifies co-firing coal with charcoal at a ratio of 8:2 as the most feasible alternative, followed by wood pellets and subcoal. The study emphasises the need for further research to refine the methodology and address setbacks associated with all alternative fuels. Nevertheless, these findings can contribute to developing sustainable

strategies for achieving net carbon zero in the steel industry by 2050.

Samuel Engel | University of Manchester

Co-authors: João Quinta da Fonesca, Joe Robson (University of Manchester), Pratheek Shanthraj, Allan Harte (UKAEA)

Session Five: Wednesday 19 July, 0900-1100

MODELLING THE EFFECT OF CYCLIC HEAT LOADS ON PRECIPITATION HARDENED CuCrZr ALLOYS

Precipitate hardened CuCrZr alloys are a potential heat sink material for divertor targets in fusion reactor design, however they are not designed to be thermally stable, especially at fusion relevant temperatures. Due to the practical restrictions of replicating fusion environments, modelling methods are needed in design, however there have been only limited efforts to model precipitation in CuCrZr alloys. Here we show that a multi-class Kampmann Wagner numerical (KWN) modelling framework can replicate the precipitate sequence of fcc Cr in Cu. The calibrated model was used to assess how cyclic heat loads accelerate precipitate

coarsening, and by coupling with a standard precipitation strengthening model, it was found

that the alloy strength will degrade noticeably within the expected time in service.

Ashutosh Gupta | University of Manchester

Session Five: Wednesday 19 July, 0900-1100

ADVANCING GEAR OIL INSIGHTS -TRIBOFILM AND SUBSURFACE CORRELATION FOCUSING ON

ASHLESS VERSUS ORGANOMETALLIC CHEMISTRIES

This study specifically focused on the hardened AISI 52100 steels used as bearing material since bearing failures are more widespread inside the wind turbine gear box. In this work, two industrial-based gear oils were examined to investigate the influence of bulk oil temperature and contact pressure on the tribological performance as well as the changes that occurred underneath the metal surfaces that are in contact. The findings show that surface-additive interaction is predominantly enhanced by low- friction tribofilms that are produced when chemical additives are activated, which depends on a suitable bulk oil temperature and results also revealed the microstructural changes occurred due to impact of tribofilm.

Tina Sadet Hashemi | Dublin City University

Co-authors: Mert Celikin (University College Dublin), Tanya Levingstone, Nicholas Dunne (Dublin City University)

Session Two: Tuesday 18 July, 1130-1300

ENHANCED CORROSION RESISTANCE OF BIODEGRADABLE PURE MAGNESIUM MODIFIED BY CALCIUM PHOSPHATE COATING FOR ORTHOPAEDIC APPLICATION

Magnesium and its alloys have been identified as a new generation of biodegradable metallic implants, however, rapid corrosion of Mg alloys limits clinical applications. In this study, the influence of CaP coating on the corrosion resistance of Mg was explored. The degradation behaviour of the CaP-coated Mg specimens was evaluated using electrochemical techniques, gravimetric analysis, and quantification of hydrogen evolution. The electrochemical measurements indicated that the CaP-coated reduced the corrosion rate of pristine Mg by eight-fold. The corrosion rate calculated by gravimetric analysis and hydrogen evolution also

showed that CaP-coated Mg specimens exhibited the lowest tendency towards corrosion.

Thomas Hughes | University of Manchester

Session Six: Wednesday 19 July, 1130-1300

MODELLING THERMAL LOADING OF PROTON BEAMS TO SIMULATE A FUSION ENVIRONMENT

Modelling irradiation damage is key to understanding how materials will respond in a fusion environment. Many simulate fusion neutron irradiation damage with protons. Protons do similar

damage, but as they are charged they interact with atoms and electrons differently to neutrons. A significant portion of energy lost during a proton’s journey through a sample is lost to the electron cloud, which can cause issues when changing beam power. Therefore this presentation aims to model the thermal impact of a proton beam for in-situ testing of fusion materials, to make sure sample temperatures are manageable.

Benjamin Jolly | University of Sheffield

Session One: Tuesday 18 July, 0900-1100

EXPLORATION OF LOCAL STRUCTURAL EFFECTS IN NICOCR TO CRYOGENIC TEMPERATURES: A

NEUTRON TOTAL SCATTERING INVESTIGATION

Noted for its strength and ductility properties, the NiCoCr multicomponent alloy is of potential interest to the nuclear sector for its perceived radiation damage suppression and high wear resistance. It is believed that the solid solution properties of the ternary system are impacted to some extent by its Short-Range Order (SRO), though such theories are as-yet untested. To explore the variation in local ordering as a function of temperature, a Neutron Total-Scattering investigation has been performed to simulate and analyse the short-range ordering behaviours of NiCoCr down to cryogenic temperatures.

Mehreen Kainat Khan | University of Manchester

Co-authors: Professor Brian Connolly, Dr. Phil Dent (University of Manchester)

Session Three: Tuesday 18 July, 1400-1545

COMPARING HYDROGEN TRANSPORT AND TRAPPING MECHANISMS CONTROLLING EMBRITTLEMENT AS A FUNCTION OF CHARGING METHOD IN STEELS

The consensus of this project is to tackle the critical issues surrounding hydrogen embrittlement. This is achieved by exploring the behaviour and variation in transport and trapping mechanisms of atomic hydrogen when interacting with steel, whereby adsorption, dissociation, and adsorption take place. The pipeline steels are subjected to demanding environments. Thus, this project focuses on developing current understanding of charging hydrogen into the metallic lattice structure across a wide range of temperatures and partial pressures. Therefore, a comparative analysis can be conducted to study the hydrogen transport and trapping mechanisms as a function of charging methods.

Hyeonseok Kim | University College Dublin

Co-authors: Dr. Eoin O’Cearbhaill, Dr. Mert Celikin (University College Dublin)

Session Three: Tuesday 18 July, 1400-1545

THE EFFECT OF MORPHOLOGY, SIZE, AND VOLUME CONTENT OF MG20CA PARTICLE ON PLA MATRIX

FILAMENT FOR 3D PRINTING

Cranial bone defects in children are a complex issue, as their bones are still growing. The use of biodegradable implants that stimulate bone regeneration can help reduce the need for multiple surgeries. Material Extrusion Additive Manufacturing  (MEAM) also known as 3D printing and magnesium (Mg) alloys play significant roles in this approach for several advantages. However, MEAM relies on filaments as the feedstock, which introduces certain challenges when working with Mg alloy powders. One of the primary hurdles encountered in MEAM is the brittleness of the filaments as the function of volume content, size, and morphology of the fillers. This study is focusing on determining the effect of morphology, size, and volume content of magnesium (Mg) alloys powder on extrudability and printability.

Theo Mossop | University College Dublin

Co-authors: Dr. David Heard (Stryker), Professor David Browne, Dr. Mert Celikin (University College Dublin)

Session Six: Wednesday 19 July, 1130-1300

ASSESSMENT OF PHASE EVOLUTION IN Ti-Ni BASED ALLOYS DURING RAPID-SOLIDIFICATION

The microstructural evolution of Ti-Nb and Ti-Nb-Ta alloys with varying cooling rates was studied using a combined simulation and experimental approach. Rods of Ti-25Nb and Ti-20Nb-10Ta (wt%) were manufactured using suction casting into cold copper moulds in diameters of 3 and 10 mm. Finite element (FE) and thermodynamic modelling were used to calculate the cooling rates and temperature gradients of the alloys. The microstructural and mechanical differences in variable cooling rapid casting and laser remelting were determined via XRD, SEM/EDS, and mechanical testing. In the binary Ti-Nb alloy, the equilibrium phases were strongly suppressed with increasing cooling rate, resulting in the formation of metastable phases. The

ternary addition of Ta further impeded the formation of equilibrium phases. The results of this study provide valuable insights to the microstructural evolution of as-solidified Ti-Nb and Ti-Nb-Ta alloys, useful for the design of Ti-based alloys for additive manufacturing applications.

Kamila Nowosad | University of Sheffield

Co-authors: Professor Daniel Cogswell, Dr. Eleanor Stillman (University of Sheffield)

Session Three: Tuesday 18 July, 1400-1545

UNCERTAINTIES ASSOCIATED WITH THE APPLICATION OF THE ASTM E1921 STANDARD PROCEDURE

The ASTM E1921 Standard provides a method of estimating fracture toughness of ferritic steels in the ductile-to-brittle transition range through the determination of the reference temperature, T0. Quantification of uncertainties associated with the procedure is necessary to understand the magnitude of the error which may accompany the reference temperature estimate. It also allows for the identification of the methodology aspects which have the greatest impact on the accuracy of the reported result. The presented work was focused on

characterisation of the assumptions and uncertainties associated with the ASTM E1921 Standard procedure. Methods of quantifying the uncertainties are also proposed.

Sian Odell | University of Manchester

Co-authors: Joe Robson, Alec Davis, Jack Donoghue (University of Manchester)

Session Seven, Wednesday 19 July, 1400-1545

NOVEL ZIRCONIUM REFINED MAGNESIUM ALLOYS

Mg alloys are an attractive alternative to Al or Ti for use in weight critical applications or for

increasing fuel efficiency. More recently there has been high interest in Mg-rare earth alloys

due to their improved mechanical and corrosion properties. With specific transition metal

additions these Mg-rare earth alloys form a long period stacking ordered phase (LPSO) which

has been found to further improve these properties. In this study the Mg-Zn-Gd-Zr alloy system

has been investigated. The microstructure has been controlled through heat treatment and chemical composition. The LPSO phase has been characterised and the three-dimensional

morphology discovered. The interaction between the LPSO and Zr addition is of great interest

in order to understand and maximise the mechanical and corrosion properties of these Zr

refined LPSO forming alloys.

Darragh O’Neil | Dublin City University

Co-authors: Rob O’Connor, Timo Gans, Deborah O’Connel (Dublin City University)

Session Seven, Wednesday 19 July, 1400-1545

THE EFFECT OF PLASMA PARAMETERS OF THIN FILMS GROWN BY PLASMA ENHANCED ATOMIC LAYER DEPOSITION

Plasma enhanced atomic layer deposition (PEALD) is a powerful thin film deposition technique that can produce uniform and conformal films with precise control of the thickness and composition. However, the plasma parameters used during PEALD strongly influence the resulting film properties, making their optimisation a critical aspect of deposition processes. This study investigates the influence of several plasma parameters on film deposition. To gain deeper insights into the plasma characteristics, non-invasive optical emission spectroscopy is utilised for in-situ plasma diagnostics, providing essential information for improving the deposition processes and achieving optimal film properties.

John Power | University College Dublin

Co-authors: Owen Humphries (University College Dublin), Mark Hartnett (Irish Manufacturing Research), Denis P. Dowling (University College Dublin)

Session Seven, Wednesday 19 July, 1400-1545

APPLICATION OF IN-SITU PROCESS MONITORING TO OPTIMISE LASER PARAMETERS DURING THE L-PBF PRINTING OF Ti-6Al-4V PARTS WITH OVERHANG STRUCTURES

Laser powder bed fusion has become a popular additive manufacturing method due to its ability to create complex and customisable designs. However, overhang structures can pose challenges, as they lead to overheating in the overhang meltpool, which can cause print defects e.g. porosity. In-situ process monitoring has been found to be an effective solution for detecting and correcting these defects in real-time. By monitoring the meltpool temperature, the laser energy can be precisely controlled to avoid overheating, resulting in a significant reduction in roughness and porosity. This monitoring process is based on photodiode IR measurements and also allows for the optimisation of the microstructure of the printed structure.

Dennis Premoli | University of Sheffield

Co-authors: Joshua Taylor (University of Sheffield)

Session Seven, Wednesday 19 July, 1400-1545

FORCE-FEEDBACK ANALYSIS

The research presented aims to demonstrate the capabilities of Force Feedback Analysis (FFA) to capture microstructural data from machined Ti-6Al-4V round discs obtained from UD-rolled material. Of particular interest are areas of unidirectional crystallographic texture known as macrozones, which have been shown to be potential nucleation sites for a cold dwell fatigue failure mechanism. The force feedback maps produced identified the existence and direction of a strong rolling texture, as well as large-scale macrozone features, a crucial advancement in validating FFA as a novel in-process characterisation method.

William Robertson | University of Sheffield

Co-authors: Dr. Richard Thackray (University of Sheffield) 

Session Seven, Wednesday 19 July, 1400-1545

ASSESSMENT OF THE ENVIRONMENTAL IMPACT OF RESIDUAL AND CRITICAL ELEMENTS IN STEEL: REMOVAL, RECOVERY, AND SUBSTITUTION

Steel is produced using two main production processes: Blast Oxygen Furnace and Electric Arc furnace. Electric arc furnace allows for more scrap input, which could make it a more environmentally friendly production route. It is not as simple as this however, as changes to areas in a production route can affect other areas of the process. This project aims to compare the environmental impact of the two production routes using Life Cycle Assessment with the OpenLCA software. Environmental impact of recovery methods for a variety of residual elements are being assessed with the goal of improving recycled steel quality with lower impact.

Samuel Ross | Swansea University

Session Three: Tuesday 18 July, 1400-1545

DESIGN OF NOVEL HIGH ENTROPY BRAZING ALLOYS

Within the aerospace industry dissimilar alloys operating at high temperatures are often joined by brazing with suitable filler alloys. To enable joints to be manufactured at temperatures lower than intended operating temperatures, melting point depressors able to diffuse away from the joint are required in the alloy. In this work, High Entropy Alloys (HEA) fillers with Boron as a melting point depressor offer property-based customisation, and using Rapid Alloy Prototyping have been produced and applied to braze joints with testing of the materials showing potential for development and use in high temperature applications.

Josephine Ryan Murphy | Dublin City University 

Session Five: Wednesday 19 July, 0900-1100

INVESTIGATION THE EFFECT OF HEAT TREATMENT ON ELECTRO-MECHANICAL NITINOL ACTUATORS

This study investigates the effect of heat treatment on the performance of electro-mechanical shape memory nitinol actuators. Shape memory alloys are a promising alternative to traditional actuation methods as they generally require fewer components, less space, and have lower mass. For this investigation samples of nitinol wire with active 𝐴𝑓 of 0, 14, and 25˚C were heat treated at 350, 400, and 450˚C, for 30, 60, and 90 minutes. The actuators were then evaluated and characterised by an in-house built rig, DSC, Keyence, EDX, XRD, and density tests to determine the optimum heat treatment parameters.

Elif Sen | University of Manchester

Session One: Tuesday 18 July, 0900-1100

MICROMECHANICS OF HETEROGENOUS CASE-CARBURISED BEARING MICROSTRUCTURES

Carburised steel microstructures are multiphase structures and include martensite, retained austenite, and carbides. However, depending on the carburisation parameters used, there is usually a change in the number of near-surface carbides, grain size, carbon content, volume ratio, and local environment of metastable austenite. Therefore, there is an industrial need to prove the mechanics of carburised bearing steels through their thicknesses. Studies are desirable to correlate the local microstructure and production of bearing steels with their mechanical behaviour. It will help to maximise these materials' functionality, reliability, and durability, and to understand their micromechanics.

Ali Shayegh | University College Dublin

Co-authors: Philip Cardiff (University College Dublin)

Session One: Tuesday 18 July, 0900-1100

THE COMPARATIVE STUDY OF OPENFOAM AND ABAQUS IN CONTINUOUS FORMING PROBLEMS

In this work, we present a comparative study of OpenFOAM and Abaqus for continuous forming problems. Two benchmark problems, namely rolling and drawing, are used to assess the performance of the two software in terms of accuracy, convergence speed, and scalability. The study is motivated by the need for accurate and efficient simulation tools for continuous forming processes in manufacturing industries. Both OpenFOAM and Abaqus are widely used for simulating finite volume and finite element analysis, respectively. However, their comparative performance in continuous forming problems is not well-established.

For the rolling benchmark, we simulate the process of a billet being flat-rolled into a bar using both OpenFOAM and Abaqus. The simulations are run using a range of mesh sizes and time steps to assess the accuracy and convergence speed of the two software. The drawing benchmark involves the simulation of the process of drawing a cylindrical bar into a cylindrical bar with a smaller diameter. The same mesh and time step sizes will be used in both software. We expect our results show that both OpenFOAM and Abaqus can simulate continuous forming processes with high accuracy. However, which one is faster in terms of convergence speed and also easier to set up, especially for complex geometries remains to be answered. The same question applies to scalability, i.e., which one may handle larger problems with better efficiency. The findings will provide insights into the strengths and weaknesses of OpenFOAM and Abaqus in simulating continuous forming processes and can guide the selection of software for specific applications.

Alexander Sloane | University of Sheffield

Session Five: Wednesday 19 July, 0900-1100

THE EFFECT OF PART GEOMETRY ON MELT POOL GEOMETRY IN LASER POWDER BED FUSION

Laser Powder Bed Fusion Additive Manufacturing (L-PBF AM) has the potential to revolutionise a wide range of manufacturing sectors, from automotive and aerospace, to biomedical devices. Before the process is mature enough for widespread adoption, however, further research is required to better understand the links between machine parameters and part quality. This study attempts to identify the effect that part geometry (i.e. the presence or absence of overhangs, corners, edges, and bulk sections) has on the width, depth, and length of the melt pool, and the melt pool's likelihood towards conduction or keyholing mode melting. The ultimate aim of the research project is to develop models that predictively inform L-PBF AM users which machine parameters are suitable for any given section, of any given part, to result in fully dense builds with desirable mechanical properties.

Joshua Taylor | University of Sheffield

Co-authors: Dennis Premoli, Martin Jackson (University of Sheffield), Rachid M’Saoubi (SECO Tools AB)

Session Two: Tuesday 18 July, 1130-1300

DEVELOPMENT OF A MACHINGING FORCE-BASED TECHNIQUE FOR NON-DESTRUCTIVE EVALUATION OF MICROSTRUCTURAL FEATURES IN TITANIUM ALLOYS

Aerospace component testing is costly and time-consuming, requiring skilled operators to perform techniques such as chemical etching, ultrasound, and eddy current testing. A new method utilising machining force measurements is being developed to examine material structure in titanium alloys, allowing for the visualisation of microstructural features. This technique has the potential to save time and money by detecting texture through an onboard measurement system. The digital fingerprint produced at each step will be invaluable for failure analysis on future components.

Jacob Whittle | University of Sheffield

Co-authors: Stephen Danks (British Steel), Iwo Slodczyk, David Fletcher (University of Sheffield)

Session Six: Wednesday 19 July, 1130-1300

USING DIGITAL IMAGE CORRELATION (DIC) TO MEASURE RAILWAY BALLAST MOVEMENT IN FULL-SCALE LABORATORY TESTING OF SLEEPER LATERAL RESISTANCE

A fast and accurate method is described for determining the surface movement of railway ballast during a full-scale lateral resistance test. The proposed method utilises commodity camera equipment and open-source Digital Image Correlation (DIC) algorithms. It does not require time intensive ballast preparation. Tests have been performed under ambient and floodlit conditions, using colour and greyscale processing routes. The results are compared against direct measurements from lateral resistance tests to assess the accuracy of the proposed method, with a range of absolute maximum error between 0.9% and 3.4% under different laboratory conditions. The study shows that this technique is a viable way to track and measure ballast and sleeper movement over wide areas in near real time, which will lead to an increased understanding of the way ballast interactions influence track behaviour.