Constellium has unique facilities for recycling aluminium alloys via direct extrusion into sheet. This process has cost and sustainability benefits in support of Constellium’s long-term goal of reducing CO2 emissions to 1kg per 1kg of aluminium but it potentially introduces variability into the alloy chemistry and impacts on downstream formability and final properties. 

Direct extrusion results in differences in microstructure, crystallographic texture, and how they are distributed across and through the sheet compared with traditional rolled material. Forming limit diagrams and mechanical property data is not available for this extruded material which impacts the design and optimisation of subsequent forming processes such as roll bending.

This project seeks to, for the first time, develop a forming assessment strategy for extruded recycled 6000 series aluminium with a particular focus on roll bending.

The main research tasks are:

• assessment and validation of sub-size samples for characterisation of Forming Limit Diagrams and benchmark these against standard material
• the use of novel forming assessment methodologies for characterising the material response to non-standard deformation conditions experienced during roll bending
• correlate these with the microstructure and texture of the material
• in parallel with the experimental work, model the roll bending process to understand the complex deformation paths experienced to assess the suitability of forming assessment methodologies
• assess A, B and C as a function of natural ageing from as extruded to 1 or 2 months
• investigate batch to batch variability

This project fits within EPSRC’s Advanced manufacturing and clean growth and Materials engineering – metals and alloys within the Manufacturing and the circular economy and Advanced materials themes.

Further information

Your time will be split between the AFRC the University of Strathclyde and Constellium UK Ltd. You will be part of a cohort of doctoral researchers based at AFRC and the wider NMIS Doctorate Centre in Advanced Manufacturing and Dept of Mechanical and Aerospace Engineering doctoral community at Strathclyde offering opportunities to develop your professional network and transferrable skills.  

In addition, you will complete formal training leading to a Postgraduate Certificate in Researcher Professional Development (PG Cert RPD), the first UK academic award recognising postgraduate research skills. This training, combined with research, publication, presentation at conferences, possible teaching opportunities and collaboration with Constellium, will provide a multidisciplinary skillset preparing you for careers in academia and industry.