High speed multi-channel discharge machining of difficult-to-cut materials. This project aims to develop a novel approach to high speed machining of difficult-to-cut materials by resolving the contradictory surface quality and machining efficiency problem with a new theory. It is expected to advance the fundamental knowledge of electrical machining. The outcomes are new machining theories, novel methods and models of using multiple low energy sparks which occur nearly simultaneously for high spe ....High speed multi-channel discharge machining of difficult-to-cut materials. This project aims to develop a novel approach to high speed machining of difficult-to-cut materials by resolving the contradictory surface quality and machining efficiency problem with a new theory. It is expected to advance the fundamental knowledge of electrical machining. The outcomes are new machining theories, novel methods and models of using multiple low energy sparks which occur nearly simultaneously for high speed machining of a wide range of advanced materials. It should significantly increase machining speed and thus dramatically reduce the costs of producing products such as titanium medical implants, alloyed engine components and new cutting tools which are vital for the biomaterials, aerospace and manufacturing industries.Read moreRead less
Net-shape micro manufacturing of composite micro channels. This project aims to develop a high precision net-shape micro manufacturing technology for the production of composite micro channels in a one-step process with excellent overall performance in quality and productivity. The new technology will enhance the production of commercial micro channels which have extensive applications in micro-electromechanical systems, health, medical and communications industries. This project will improve th ....Net-shape micro manufacturing of composite micro channels. This project aims to develop a high precision net-shape micro manufacturing technology for the production of composite micro channels in a one-step process with excellent overall performance in quality and productivity. The new technology will enhance the production of commercial micro channels which have extensive applications in micro-electromechanical systems, health, medical and communications industries. This project will improve the competitive advantage for Australia in the field of advanced manufacturing and has the potential to stimulate economic benefit and growth of the manufacturing industry.Read moreRead less
Ductile grinding mechanism and technology of brittle single crystals. This project aims to develop a fundamental understanding of the removal mechanics of emerging brittle single crystals under grinding-induced loading. A successful outcome will not only develop a new theoretical model for predicting the ductile removal regime of this class of difficult-to-machine materials, but their cost-effective ductile grinding processes will also be generated. It will address a longstanding bottleneck prod ....Ductile grinding mechanism and technology of brittle single crystals. This project aims to develop a fundamental understanding of the removal mechanics of emerging brittle single crystals under grinding-induced loading. A successful outcome will not only develop a new theoretical model for predicting the ductile removal regime of this class of difficult-to-machine materials, but their cost-effective ductile grinding processes will also be generated. It will address a longstanding bottleneck productivity issue in advanced manufacturing. The breakthrough technology developed in the project is expected to significantly benefit a number of industrial sectors for the fabrication of more affordable high-performance devices including mobile phones, light-emitting diodes, solar cells, sensors, and laser systems.Read moreRead less
A new lapping process for difficult-to-machine brittle materials. This project aims to address a timely bottleneck issue in the conventional lapping of difficult-to-machine optoelectronic brittle materials. An innovative chemically enhanced lapping technology for fabricating such materials is expected to reduce machined subsurface damage. This is significant because it would shorten the subsequent finishing process and minimise the manufacturing cost. Intended outcomes from this project also inc ....A new lapping process for difficult-to-machine brittle materials. This project aims to address a timely bottleneck issue in the conventional lapping of difficult-to-machine optoelectronic brittle materials. An innovative chemically enhanced lapping technology for fabricating such materials is expected to reduce machined subsurface damage. This is significant because it would shorten the subsequent finishing process and minimise the manufacturing cost. Intended outcomes from this project also include an advanced machining theory and innovations in material removal characterisation. This breakthrough technology should benefit the design and fabrication of high performance electronic devices for energy, medicine and communication sectors with considerable impact on the Australian economy.Read moreRead less
Mechanics of the shape of thin strip with varying thickness. This project aims to develop an innovative technology for the production of thin strip with controlled varying longitudinal thickness and shape. The project will propose a new thin strip rolling theory and strip shape control strategy providing an improved understanding of the mechanics of manufacturing thin strips with varying longitudinal thickness. The technology to manufacture rolled products with varying thickness for lightweight ....Mechanics of the shape of thin strip with varying thickness. This project aims to develop an innovative technology for the production of thin strip with controlled varying longitudinal thickness and shape. The project will propose a new thin strip rolling theory and strip shape control strategy providing an improved understanding of the mechanics of manufacturing thin strips with varying longitudinal thickness. The technology to manufacture rolled products with varying thickness for lightweight structures is in significant demand for the automotive, aerospace and electronics industries to reduce weight through optimum strip thickness and minimum joints. The benefits will include reduced weight, fuel consumption and construction time of automobiles and aircraft when the developed novel thin strip products are used, and therefore reducing manufacturing costs and negative environmental impacts.Read moreRead less
Characterization, modelling and control for robotic thermal ablation. This project aims to study the fundamental issues in robotic-assisted minimally invasive thermal ablation, an important therapy for patients with cancer. It aims to establish advanced characterisation and modelling methodologies for thermomechanical behaviours of soft tissues, together with automatic planning and precise manipulation control techniques for robotic thermal ablation therapies. The project will establish new know ....Characterization, modelling and control for robotic thermal ablation. This project aims to study the fundamental issues in robotic-assisted minimally invasive thermal ablation, an important therapy for patients with cancer. It aims to establish advanced characterisation and modelling methodologies for thermomechanical behaviours of soft tissues, together with automatic planning and precise manipulation control techniques for robotic thermal ablation therapies. The project will establish new knowledge and instrumentation for robotic-assisted thermal ablation and minimally invasive surgery. The outcomes of this project will produce important benefits to medicine, healthcare and medical technology industry, and further consolidate Australia’s position in innovative technologies and research and development of advanced healthcare systems and instruments.Read moreRead less
Fundamental research advancing remanufacturing with a 3D printing technique. 3D printing manufactures items directly from a computer model. This project aims to develop a computational tool for applying direct laser metal deposition, a 3D-printing method, to repair metallic components and develop a way to predict the remaining life of the remanufactured components. The tool should optimise use of this printing method and improve the quality of repaired components. The research expects to validat ....Fundamental research advancing remanufacturing with a 3D printing technique. 3D printing manufactures items directly from a computer model. This project aims to develop a computational tool for applying direct laser metal deposition, a 3D-printing method, to repair metallic components and develop a way to predict the remaining life of the remanufactured components. The tool should optimise use of this printing method and improve the quality of repaired components. The research expects to validate the tool for simulating the printing process, provide a better heat treatment during repair, and allow safe prediction of the service life of repaired components. This research should benefit the Australian manufacturing industry and reduce resource use by helping apply this 3D printing method in remanufacturing.Read moreRead less
Improvement of Additive Manufacturing Processability of Alloys and Ceramics. As the current materials that can be additively processed are still very limited, this project aims to increase the additive manufacturing processability of commercial engineering materials through developing effective and practical grain refinement technology so that more engineering parts can be additively fabricated. The project expects to widen the applications of this advanced manufacturing technology in industry p ....Improvement of Additive Manufacturing Processability of Alloys and Ceramics. As the current materials that can be additively processed are still very limited, this project aims to increase the additive manufacturing processability of commercial engineering materials through developing effective and practical grain refinement technology so that more engineering parts can be additively fabricated. The project expects to widen the applications of this advanced manufacturing technology in industry productions. Expected outcomes include commercialisation ready grain refinement technologies and breakthrough fundamental understanding of the physical metallurgy of melt pools. This should enhance Australia’s capability to establish world-leading additive manufacturing activities serving to various other industry sectors. Read moreRead less
In-situ grain boundary engineering via metal additive manufacturing. We aim to develop a capability for targeted specialty alloy microstructure design via metal 3D printing. Our approach to generate customised grain boundary networks in stainless steels and superalloys will unlock superior mechanical, corrosion and technological properties, without subsequent thermomechanical treatments. Scientific outcomes are new physical metallurgy knowledge on the targeted selection of desirable interfaces v ....In-situ grain boundary engineering via metal additive manufacturing. We aim to develop a capability for targeted specialty alloy microstructure design via metal 3D printing. Our approach to generate customised grain boundary networks in stainless steels and superalloys will unlock superior mechanical, corrosion and technological properties, without subsequent thermomechanical treatments. Scientific outcomes are new physical metallurgy knowledge on the targeted selection of desirable interfaces via recrystallisation and coupled segregation-precipitation phenomena. Technological outcomes are processing maps for printing parts with customised microstructures. This will diminish anisotropy, residual stress and defects, benefitting defence, aerospace and energy applications, all vital to the Australian economy.Read moreRead less
Superwettability effects on oil-mist coalescing fibrous filters. This project aims to provide new knowledge about how to use surface engineering techniques to produce highly efficient, energy-saving fibrous filters for separating oil mists from air streams. The focus is to address the challenge of the low efficiency of current generation coalescing filters for removal of oil mists smaller than one micrometre. The project will result in new methods to precisely control fibre surface wettability a ....Superwettability effects on oil-mist coalescing fibrous filters. This project aims to provide new knowledge about how to use surface engineering techniques to produce highly efficient, energy-saving fibrous filters for separating oil mists from air streams. The focus is to address the challenge of the low efficiency of current generation coalescing filters for removal of oil mists smaller than one micrometre. The project will result in new methods to precisely control fibre surface wettability and oil drainage within fibrous filters. The new knowledge and coalescing filters developed will benefit scientific and industrial fields including metal processing, automotive, engineering and manufacturing, electronics, food, hospital, mining, pharmaceuticals and energy generation.Read moreRead less