Structure-property relationships of next generation aero-engine materials. We aim to design a novel manufacturing process for superalloy aero-engine parts with superior mechanical properties. This is significant because optimisation of the hot-forging route of the most commonly used Alloy 718 will enable targeted control of its nanoscale precipitate microstructure leading to substantial increases in the high-temperature strength. The expected scientific outcomes are new physical metallurgy knowl ....Structure-property relationships of next generation aero-engine materials. We aim to design a novel manufacturing process for superalloy aero-engine parts with superior mechanical properties. This is significant because optimisation of the hot-forging route of the most commonly used Alloy 718 will enable targeted control of its nanoscale precipitate microstructure leading to substantial increases in the high-temperature strength. The expected scientific outcomes are new physical metallurgy knowledge of the microstructure-property relationships of superalloys. The expected technological and societal outcomes include enhanced aero-engine material performance, creating benefits such as shorter flights over longer distances, and safer, more fuel-efficient air travel.Read moreRead less
Advancing the Australian specialty alloy processing capability. This project aims to advance Australia’s specialty alloy processing capability by developing novel processing routes to overcome current bottlenecks that prevent supply meeting demand. New knowledge will be generated on alternative means of the processing of Rene 41, a Nickel-based superalloy with limited formability through a comprehensive experimental and modelling-based research program. Rene 41 is strategically important for man ....Advancing the Australian specialty alloy processing capability. This project aims to advance Australia’s specialty alloy processing capability by developing novel processing routes to overcome current bottlenecks that prevent supply meeting demand. New knowledge will be generated on alternative means of the processing of Rene 41, a Nickel-based superalloy with limited formability through a comprehensive experimental and modelling-based research program. Rene 41 is strategically important for manufacturing next generation turbofan engines. The expected outcome is the identification of innovative processing routes to provide stronger, defect-free specialty alloys for aerospace applications, vital to Australia’s advanced manufacturing.Read moreRead less
Next generation flexible high current micro-electronic interconnects. The project aims to reduce the temperatures required for the manufacture of electronic circuitry through the use of low melting temperature metallic gallium-based alloys. The project will use a range of innovative techniques to generate methods that these low temperature alloys can rapidly transition from a liquid state to a solid intermetallic in short timeframes at low-temperatures. The outcomes from this project include red ....Next generation flexible high current micro-electronic interconnects. The project aims to reduce the temperatures required for the manufacture of electronic circuitry through the use of low melting temperature metallic gallium-based alloys. The project will use a range of innovative techniques to generate methods that these low temperature alloys can rapidly transition from a liquid state to a solid intermetallic in short timeframes at low-temperatures. The outcomes from this project include reduced energy costs during electronic manufacture and the development of techniques that will enable sensitive next-generation components to be assembled by removing the need to use elevated temperatures.Read moreRead less
Embrittlement-tolerant alloys for safe hydrogen transmission and storage. Hydrogen embrittlement in steels is a major impediment to a safe hydrogen economy. This project will determine how hydrogen affects the deformation behaviour of steel, providing the fundamental information that is required to develop alloys that can be safely used in infrastructure for a future Australian hydrogen industry. We will utilise new technologies that allow us, for the first time, to determine the position of hyd ....Embrittlement-tolerant alloys for safe hydrogen transmission and storage. Hydrogen embrittlement in steels is a major impediment to a safe hydrogen economy. This project will determine how hydrogen affects the deformation behaviour of steel, providing the fundamental information that is required to develop alloys that can be safely used in infrastructure for a future Australian hydrogen industry. We will utilise new technologies that allow us, for the first time, to determine the position of hydrogen atoms around micro-scale features and to compare it to local mechanical behaviour, determined by micro-mechanical tests. The systematic investigation of the effect of hydrogen on different micro-components within steel will allow the development of microstructure-guided alloy design principles.Read moreRead less
Systematic investigations of low temperature Sn-Bi based solder alloys . The project aims to reduce the temperatures used in the manufacture of electronic circuitry through the development of Sn-Bi alloys for low temperature assembly processes without compromising productivity or reliability. The project will use a range of innovative solidification and microstructure development techniques to obtain an understanding of the dynamic processes of precipitation, dissolution and microstructure evolu ....Systematic investigations of low temperature Sn-Bi based solder alloys . The project aims to reduce the temperatures used in the manufacture of electronic circuitry through the development of Sn-Bi alloys for low temperature assembly processes without compromising productivity or reliability. The project will use a range of innovative solidification and microstructure development techniques to obtain an understanding of the dynamic processes of precipitation, dissolution and microstructure evolution that occur in these alloys during manufacture and application. The outcomes include a reduction in the energy consumed in electronic assembly processes and a capacity to manufacture advanced circuitry based on next-generation temperature-sensitive components and substrates without compromising reliability.Read moreRead less
Lower-cost processing of formable magnesium alloys. This project aims to develop higher speed extrusion and rolling of magnesium alloys through the enhanced control of alloying elements and processing schedules. Expected outcomes of this project include the development of novel alloys and processing technologies that can produce lighter, better performing magnesium products with lower processing costs. This project will deliver magnesium products that can improve fuel efficiency, resulting in lo ....Lower-cost processing of formable magnesium alloys. This project aims to develop higher speed extrusion and rolling of magnesium alloys through the enhanced control of alloying elements and processing schedules. Expected outcomes of this project include the development of novel alloys and processing technologies that can produce lighter, better performing magnesium products with lower processing costs. This project will deliver magnesium products that can improve fuel efficiency, resulting in lower emissions and less environmental pollution, along with lightweight portable consumer goods.Read moreRead less
Advanced shield materials for compact fusion energy. We aim to predict how materials used for shielding sensitive components in nuclear fusion reactors will degrade over time. We will use this knowledge to design advanced alloys for radiation shield, which are critical for the development of more compact fusion reactors design, with lower construction cost, and shorter assembly time. These advanced shield materials may also be used in other applications in radiation fields (e.g. space, nuclear m ....Advanced shield materials for compact fusion energy. We aim to predict how materials used for shielding sensitive components in nuclear fusion reactors will degrade over time. We will use this knowledge to design advanced alloys for radiation shield, which are critical for the development of more compact fusion reactors design, with lower construction cost, and shorter assembly time. These advanced shield materials may also be used in other applications in radiation fields (e.g. space, nuclear medicine). The project also seeks to extend the Australian nuclear research capability by developing an innovative technique to study radiation damage using the OPAL reactor at ANSTO.Read moreRead less
Sustainable and robust Australian Ni-based superalloy manufacturing. This project aims to solve challenges related to microstructural defect formation in the manufacturing of a critical Ni-based superalloy. It will generate new knowledge on its microstructure evolution and defect origin via a combined experimental and computational approach. Expected outcomes are advanced manufacturing routes with higher yield of defect free materials, using more scrap as input. This will enable robust and susta ....Sustainable and robust Australian Ni-based superalloy manufacturing. This project aims to solve challenges related to microstructural defect formation in the manufacturing of a critical Ni-based superalloy. It will generate new knowledge on its microstructure evolution and defect origin via a combined experimental and computational approach. Expected outcomes are advanced manufacturing routes with higher yield of defect free materials, using more scrap as input. This will enable robust and sustainable alloy manufacturing for power generation, defence, and aerospace industries. Commercial benefits are opportunities to domestically source alloys with reduced dependency on international trade. Environmental and societal benefits include lower emissions due to better mechanical design and workforce training.Read moreRead less
Computational alloy design for cold spray deposition. The aim of this project is to design a new generation of proprietary, high performance alloys and composites that are optimised for cold spray deposition. Cold spray is a new manufacturing technology that is used to create coatings for enhancement, repair, restoration and for additive manufacturing. Using a systems approach and by integrating experiment with computational models, this project will generate new knowledge for enhanced materials ....Computational alloy design for cold spray deposition. The aim of this project is to design a new generation of proprietary, high performance alloys and composites that are optimised for cold spray deposition. Cold spray is a new manufacturing technology that is used to create coatings for enhancement, repair, restoration and for additive manufacturing. Using a systems approach and by integrating experiment with computational models, this project will generate new knowledge for enhanced materials design. Partnering with Ruag Australia, a leading Defence aerospace supplier, the project will deliver a practical tool for the accelerated design of metal powders for cold spray and invent commercially useful advanced materials to improve the competitiveness of Australian manufacturing industry.Read moreRead less
Mitigating hydrogen embrittlement in high-strength steels. Hydrogen wreaks havoc in many alloys, leading to embrittlement that can cause catastrophic failure. This is a very serious issue for any industry in which structures are exposed to hydrogen and is a limiting factor for the production, transport, storage and use of hydrogen in a potential hydrogen economy. However, understanding the behaviour of hydrogen in alloys is restricted by the difficulty of observing it. In this project we will ob ....Mitigating hydrogen embrittlement in high-strength steels. Hydrogen wreaks havoc in many alloys, leading to embrittlement that can cause catastrophic failure. This is a very serious issue for any industry in which structures are exposed to hydrogen and is a limiting factor for the production, transport, storage and use of hydrogen in a potential hydrogen economy. However, understanding the behaviour of hydrogen in alloys is restricted by the difficulty of observing it. In this project we will obtain accurate 3D maps showing the position of hydrogen atoms in steel by combining deuteration with cryogenic atom probe microscopy. In this way we will will elucidate how a proposed solution, hydrogen trapping, reduces hydrogen embrittlement, contributing to design criteria for hydrogen-resistant steels.Read moreRead less