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Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Alcan Aluminium Intensive Vehicles (AIVs) 1983 to 1993
Range Rover Sport
Range Rover Sport
Range Rover Sport
Range Rover Sport
Range Rover Sport
Range Rover Sport
Current JLR Aluminium Applications
Current JLR Aluminium Applications
Current JLR Aluminium Applications
Current JLR Aluminium Applications
EU Aluminium Automotive Sheet Production Growth (kt)
EU Aluminium Automotive Sheet Production Growth (kt)
Alcoa Heat Treatment and Finishing: Davenport
Alcoa Heat Treatment and Finishing: Davenport
Jaguar F-type
Jaguar F-type
Jaguar F-type
Jaguar F-type
Jaguar F-type
Jaguar F-type
Jaguar F-type
Jaguar F-type
Range Rover Sport Sand Cast Rear Subframe
Range Rover Sport Sand Cast Rear Subframe
Research Vision and Ambition
Research Vision and Ambition
Research Vision and Ambition
Research Vision and Ambition
Project Objectives
Project Objectives
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
REALCAR 2
Advanced Light Metals Processing Research Centre
Advanced Light Metals Processing Research Centre
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Aluminium Research for Road Transport Applications

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1Aluminium Research for Road Transport 19from one specially designed cast Al-alloy.
Applications. Geoff Scamans Innoval TARF-LCV aims to develop such Al-alloys,
Technology and Brunel University. for body sheet, for cast body parts and
2Alcan Aluminium Intensive Vehicles for powertrain components.
(AIVs) 1983 to 1993. BL Metro AIV. Bertone 20Recyclable Aluminium BIW. Magnesium
Fiat X1/9 AIV. Ford Taurus/Sable AIV. Six content is not an issue AlSi casting
AIV replica British Leyland Metros were alloys result in a high silicon level in
built in 1983. The sheet moncoque body the remelted BIW alloy AlMg casting alloys
structure was built from AA5251 sheet are a promising alternative (RASCAL TSB
while the closure panels consisted of project) Tolerance of iron is important
standard steel components. Five AIV for casting, sheet and extrusion alloys
replica Bertone Fiat X1/9s were built in (RecycAL FP7 project) Recycled alloys
1986 using AA5251 sheet for the monocoque should be used for both the closure panel
and AA6010 for the closure panels. A build and structure.
of 40 Mercury Sable AIVs was completed in 21TSB funding in the area of light
1993 using AA6111 sheet for closure panels metals (aluminium and magnesium) This
and AA5754 sheet for the monocoque chart includes collaborative R&D
structure. The structure was not projects with a significant light metal
redesigned yet a weight saving of 46% was content that have been funded from
achieved. competitions from 2004 to 2013. The
3Range Rover Sport. figures represent the total value of the
4Range Rover Sport. project. TSB typically provides 50% of the
5Current JLR Aluminium Applications. funding support inline with state aid
6Passenger Vehicle Emissions (ICE) 2012 rules. 2005. 2006. 2007. 2008. 2009. 2010.
UK vehicles. 2011. 2012. 2013. 2014. 2015. 2005. 2006.
7EU Aluminium Automotive Sheet 2007. 2008. 2009. 2010. 2011. 2012. 2013.
Production Growth (kt). body structures 2014. 2015. Upcycling of Light Alloys by
(20%) closures (80%). Rheoforming Scrap (ULARS) Innoval,
8EU Growth in Aluminium Automotive Meridian, Norton Aluminium, Zyomax and
Sheet Continuous Heat Treatment Capacity Brunel ?1,614,996. Recyclable Ultra Light
(kt). Mixed material Automotive Platform
9Alcoa Heat Treatment and Finishing: (RULMAP) Innoval, IQuad, Atlas Composites,
Davenport. Boal and Oxford ?768,317. Manufacturing.
10NA Growth in Aluminium Automotive CAE reliability tools and design methods
Sheet Continuous Heat Treatment Capacity for structures with hybrid bonded joints
(kt). (BONDEDCAR) JLR, Coventry, nCode, Stoke
11Jaguar F-type. Golding, Novelis, Dow, Innoval, and Henrob
12Projected Growth for Extrusion in Key ?1,218,135. Warm Aluminium Forming
Automotive Applications (kt). This Technology (WAFT) JLR, Dutton, Innoval,
analysis based on the predicted growth in Novelis, Stadco, Whiston, Fuchs and
EU27 vehicle production from 17.2 million Imperial ?2,842,974. Plastic Net-Forming
in 2012 to 30 million in 2025, the of Metal (PLANET) Innoval, JLR, Corus,
increase of aluminium in vehicles from Plastic Omnium, Sabic and Warwick
140kg/vehicle to 220 kg/vehicle and the ?496,098. Aluminium Matrix Composite
progressive increase in extrusions in the Materials for vehicle Weight Reduction
mix from 10 to 15%. The estimate for body JLR, Composite Metal Technolgy, Antich
may be high if sheet intensive vehicle ?2,115,281. A20X High Value Large
construction predominates. Structure Casting Aeromet, LSM, JLR, JVM,
13Range Rover Sport Sand Cast Rear University of Birmingham ?830,300.
Subframe. Hi-TINAL: Advanced High-Tin Aluminium
14EPSRC funding in the area of light Plain Bearing Alloys Rolls Royce, Brunel,
metals This chart includes funding in the KC Engineering ?542,682. Magnesium
area of light metals, either current or Intensive BIW Structures for the Premium
announced, in April 2013. Grants are Automotive Sector Morgan, Penso, MEL,
grouped into categories. The named Coventry University, Luxfer ?1,415,154.
investigators and institutions are those Light weight 7.5 - 12 tonne Future Truck
for the Principal Investigators on the Chassis Concept Leyland Trucks, Sapa, MI
grant and the figures represent EPSRC’s Technology ?1,252,530. Novel Aluminium
contribution (80% FEC). Some grants will Dross/Salt Slag Press Technology Altek
have a complete light metals focus, others ?626,622. High quality surface finished
(in particular large grants) will have aluminium rollers for mass replication
other metals and materials as aspects of (REPLICAL) Innoval, Macdermid, Stockfield
their research. 2005. 2006. 2007. 2008. ?413,970. Grain refiner for lightweight
2009. 2010. 2011. 2012. 2013. 2014. 2015. aluminium automotive castings Innoval,
2016. 2017. 2018. 2005. 2006. 2007. 2008. Grainger & Worrall, ESI-Group, LSM and
2009. 2010. 2011. 2012. 2013. 2014. 2015. JLR ?705,418. Aluminium Lattice Structures
2016. 2017. 2018. DTC in Advanced Metallic via Additive Manufacturing Econolyst,
Systems - Sheffield/Manchester - Alcon, Axon, Delcam, Delphi, Loughborough
?6,364,458. DTP in Structurally Metallic U, NottinghamU, Renishaw ?1,066,769.
Systems for Gas Turbine Applications - Recycled tolerant aluminium alloy
Cambridge/Swansea/Birmingham - ?6,819,398. utilising post consumer waste (REALCAR2)
Doctoral Training. A Centre for Doctoral JLR, Innoval, Novelis, Aleris and Warwick
Training on the Theory and Simulation of University ?980,708. Development of the
Materials – Imperial - ?6,414,829. rheo-diecasting process for lightweight
Fellowships. Industrial Doctorate Centre: automotive components (RDC) Innoval,
Micro- and NanoMaterials and Technologies Brunel University, Ford Jaguar, JVM
– Surrey - ?6,168,139. Programme Grants. Castings, Meridian, NAMTEC ?1,673,893. Key
Industrial Doctorate Centre in Advanced 2004 - 2010: Advanced Materials. Direct
Forming and Manufacture– Strathclyde- Chill RheoCasting of High Performance
?1,231,298. Centre for Innovative Aluminium Alloys (DCRC) Innoval, Alcan,
Manufacturing. Step change materials Novelis, Brunel, Luxfer Gas Cylinders,
efficiency for steel and aluminium Zyomax ?2,012,562. Structural Adhesive
-Allwood – Cambridge –- ?1,565,446. Steel Bonding of thick Components for Advanced
& Al. Strategic Partnership. Reducing Design (SABCAD) Airbus, BAE Systems,
Emissions by Exploiting Field-Induced Imperial, Surrey ?693,255. High Value
Martensitic Transformations Dye – Imperial Manufacturing. Environmental
–- ?1,151,930. Steel & Ti. Responsive Sustainability. Key 2010 - 2015:
Funding. Light Alloys Towards Technology Inspired Innovation. Lower
Environmentally Sustainable Transport Cost, Light Weight Vehicles by Increasing
LATEST2 – Thompson - Manchester – the Use of Post Consumer Aluminium Scrap
?5,762,121. Light Metals. Targeted (REALCAR) JLR, Novelis, Norton Aluminium,
Funding. Centre for Innovative Zyomax, Innoval, Brunel ?1,908,711. Limo
Manufacturing: Liquid Metal Engineering Green Jaguar, Caparo, Lotus, MIRA
Brunel/Oxford/Birmingham –- ?5,119,391. Al ?4,104,789. Resource Efficiency.
& Mg. Rolls-Royce Strategic Replacement of Copper by Aluminium in
Partnership Structural Metallic Systems Electrical Heating Cables (HEATAL) Heat
for Gas Turbines– Trace, Innoval, 3M, Whatlow and Manchester
Birmingham/Cambridge/Swansea/Sheffield – ?2,356,354. Low Carbon Vehicles. Highly
?7,521,798. Hybrid through process Innovative Technology Enablers In
modelling IMMPETUS – Sheffield – Aerospace. Innovative Microstructural
?4,517,374. SAMULET4: UFG Ti-6Al-4V for Design for Advanced Al Alloys (IDEAL)
DB/SPF and Hot-Die Forging of Titanium – Rolls-Royce, Aeromet, University of
Rosochowski, Ewing, Ion, Quin Strathclyde Birmingham ?569,453. Recyclable aluminium
- ?2,342,379. Ti. Micro- and structural casting alloy (RASCAL) JLR,
nano-patterning of titanium surfaces Dalby Innoval, JVM, Norton, Brunel University
– Glasgow ?340,919. Ti. Towards ?885,099. On-line control of Friction Stir
Affordable, Closed-Loop Recyclable Future Welding processes using ultrasonic testing
Low Carbon Vehicle Structures - TARF-LCV Thompson Friction, TWI, Theta, GKN
Brunel/Manchester/Imperial/Nottingham/Stra ?870,696. HITEA: REACH Compliant
hclyde/Exeter/Brookes/Coventry ?4,221,482. Hexavalent Chrome Replacement Rolls Royce,
Al, Mg & PMC. Cryogenic Machining GE, BAe Systems, Goodrich, Aeroengine
Systems (CRYOSIS) Newman – Bath ?224,159. Controls ?2,200,000. Ultra-light Car
Ti. Grain refiner for high performance Bodies (UlCab) PAB, Impression
light metal castings Babu Nandela – Brunel Technologies, Lotus,Innoval, Imperial
?121,144. Al. Energy saving in the Foundry College ?1,117,026.
Industry Jolly – Cranfield ?116,344. 22TSB active projects (aluminium) This
Cavitation Melt Processing: (UltraMelt) chart includes collaborative R&D
Eskin – Brunel ?340,919. Precision guided projects with a aluminium and automotive
flexible forming Allwood – content that have been funded from
Cambridge/Bath/Leeds/Trent ?1,707,194. UK competitions from 2010 to 2014. The
Indemand: a National Research Centre for figures represent the total value of the
reducing Industrial Energy and Material project. TSB typically provides 50% of the
use Allwood – Cambridge/Bath/Leeds/Trent funding support inline with state aid
?6,173,069. Centre for Innovative rules. Technology Inspired Innovation.
Manufacturing in Laser-based Production Manufacturing. Resource Efficiency. Low
Heriot-Watt/Cambridge/Cranfield/Liverpool/ Carbon Vehicles. 2010. 2011. 2012. 2013.
anchester–- ?5,571,751. Key: Strategic 2014. 2015. Aluminium Matrix Composite
Affordable Manufacturing in the UK through Materials for vehicle Weight Reduction
Leading Environmental Technology JLR, Composite Metal Technology, Antich
(SAMULET). ?2,115,281. A20X High Value Large
15EPSRC funding for aluminium research Structure Casting Aeromet, LSM, JLR, JVM,
This chart includes funding in the area of U of Birmingham ?830,300. Hi-TINAL:
light metals, either current or announced, Advanced High-Tin Aluminium Plain Bearing
in April 2013. Grants are grouped into Alloys Rolls Royce, Brunel, KC Engineering
categories. The named investigators and ?542,682. Light weight 7.5 - 12 tonne
institutions are those for the Principal Future Truck Chassis Concept Leyland
Investigators on the grant and the figures Trucks, Sapa, MI Technology ?1,252,530.
represent EPSRC’s contribution (80% FEC). Grain refiner for lightweight aluminium
Some grants will have a complete light automotive castings Innoval, Grainger
metals focus, others (in particular large & Worrall, ESI-Group, AMG and JLR
grants) will have other metals and ?705,418. Recyclable aluminium structural
materials as aspects of their research. casting alloy (RASCAL) JLR, Innoval, JVM,
2005. 2006. 2007. 2008. 2009. 2010. 2011. Norton, Brunel University ?885,099.
2012. 2013. 2014. 2015. 2016. 2017. 2018. On-line control of Friction Stir Welding
Step change materials efficiency for steel processes using ultrasonic testing
and aluminium -Allwood – Cambridge –- Thompson Friction, TWI, Theta, GKN
?1,565,446. Light Alloys Towards ?870,696. Aluminium Lattice Structures via
Environmentally Sustainable Transport Additive Manufacturing Econolyst, Alcon,
LATEST2 – Thompson - Manchester – Axon, Delcam, Delphi, Loughborough U,
?5,762,121. Centre for Innovative NottinghamU, Renishaw ?1,066,769. Recycled
Manufacturing: Liquid Metal Engineering tolerant aluminium alloy utilising post
Brunel/Oxford/Birmingham –- ?5,119,391. consumer waste (REALCAR2) JLR, Innoval,
Hybrid through process modelling IMMPETUS Novelis, Aleris and Warwick University
– Sheffield – ?4,517,374. Towards ?980,708. Ultra-light Car Bodies (UlCab)
Affordable, Closed-Loop Recyclable Future PAB, Impression Technologies, Lotus,
Low Carbon Vehicle Structures - TARF-LCV Innoval, Imperial College ?1,117,026.
Brunel/Manchester/Imperial/Nottingham/Stra 23REALCAR 2. Mechanical Biological
hclyde/Exeter/Brookes/Coventry ?4,221,482. Treatment (MBT). Aluminium from MBT. EMR
Precision guided flexible forming Allwood Media Separation. EMR Shredder. Aluminium
– Cambridge/Bath/Leeds/Trent ?1,707,194. RSIs. Aluminium Melting. DC casting. Coil
UK Indemand: a National Research Centre rolling. Consortium Partners.
for reducing Industrial Energy and 24Advanced Light Metals Processing
Material use Allwood – Research Centre. Brunel University has
Cambridge/Bath/Leeds/Trent ?6,173,069. been granted ?3.9M from the Engineering
Centre for Innovative Manufacturing in and Physical Sciences Research Council
Laser-based Production (EPSRC) for the creation of a national
Heriot-Watt/Cambridge/Cranfield/Liverpool/ scale-up facility for automotive light
anchester–- ?5,571,751. 2005. 2006. 2007. metals research initially in collaboration
2008. 2009. 2010. 2011. 2012. 2013. 2014. with Jaguar Land Rover and Constellium.
2015. 2016. 2017. 2018. Grain refiner for Brunel University will supplement this
high performance light metal castings Babu grant with a further ?5.5M for a dedicated
Nandela – Brunel ?121,144. Energy saving building and support resource at their
in the Foundry Industry Jolly – Cranfield site in Uxbridge The goal of the “Advanced
?116,344. Cavitation Melt Processing: Light Metals Processing Research Centre”
(UltraMelt) Eskin – Brunel ?340,919. Steel will be to bridge the gap between
& Al. Fellowships. Light Metals. fundamental research and industrial
Programme Grants. Centre for Innovative applications, allowing rapid exploitation
Manufacturing. Al & Mg. Responsive of innovations developed at the laboratory
Funding. Al, Mg & PMCs. Al. Key: scale The Centre aims to provide
16Towards Affordable, Closed-Loop high-performance light alloys,
Recyclable Future Low Carbon Vehicle resource-efficient casting technologies,
Structures: Metallic Materials Group extrusion processing technologies and
Objectives. BCAST, Brunel University. component innovations to meet the mid- and
Geoff Scamans. long-term needs of the automotive industry
17Research Vision and Ambition. 2011. Of strategic importance will be a fully
2030. integrated DC casting and extrusion
18Project Objectives. To develop facility, which is planned to include a
closed-loop recyclable Al-alloys and full-size 1600 ton extrusion press
self-corrosion-resistant Mg-alloys To complete with support facilities and full
develop advanced PMCs using recyclable automation, and commercial scale high
rGFs, rCFs and recoverable rNFs To develop pressure and low pressure die casting
novel technologies for liquid metal machines.
treatment to enable closed-loop recycling 25Advanced Light Metals Processing
To develop advanced technologies for LC Research Centre. Operational Q3 2014:
manufacturing and effective disassembly of 1300m2 approx.
ELVs To develop mass-optimised vehicle 26Summary. EPSRC support for aluminium
design principles To develop specific LCA and magnesium is concentrated within LiME,
methodology for future LCV development. LATEST2, TARF-LCV. These programmes
19Aluminium Alloy Development. The support a large number of RAs and PhDs The
future LCV body structure will consist of Advanced Metallics DTC supports a small
wrought Al sheet and profiles and cast Al number of aluminium PhD projects The
shaped components. At the end of vehicle support for aluminium research is broadly
life, the Al parts can be easily removed similar to that of titanium but much lower
from the ELVs for direct recycling with than the support for PMCs TSB funding to
little requirement for compositional date has supported about 20 aluminium
adjustment. Stronger more crash resistant projects to date with a total project
alloys are required for light weight value of over ?50m Most of the support is
chassis components (extrusions, forgings for automotive and aerospace related
and castings) In addition, the powertrain applications.
system should consist of components made
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