Theme 3 Surface Engineering for Low Environmental Impact and Interface Design
The aim of Theme 3 is to develop the scientific understanding required to underpin and explore creative, new, environmentally-compliant and economically viable solutions to i) enhance surface properties and performance, including reduced corrosion susceptibility, ii) facilitate joining of dissimilar materials (e.g. metals to composites) and the manufacture of hybrid materials (i.e. low density core metal skin laminates) and iii) protect multi-material structures, thus facilitating the introduction of more efficient designs.
For light alloys, corrosion control is a vital aspect of many surface treatments where, for example, local variations in microstructure impact significantly on both corrosion susceptibility and the uniformity of protective coating development. Importantly, microgalvanic effects are also decisive in determining the performance in service. Consequently, major inputs to this theme include understanding of the roles of microstructure at all length scales, including advancement of 3D electron imaging of corrosion fronts and protected systems, and local subsurface microstructures, textures and surface roughening, developed through forming and joining, on surface properties.
| Such understanding will also provide improved surface appearance and performance of formed materials from knowledge of the impact of near-surface deformed layers on optical appearance and surface integrity. For surface treatments, a more detailed knowledge of conventional anodizing and plasma electrolytic oxidation of light alloys will also enhance practical applications. In addition, other treatments including sol gel processes and conversion coating are also of importance for future, effective use of light alloys. |  |
The research is aimed at supporting the following application areas:
- Development of environmentally-friendly, economic coating routes for advanced light alloys across the transport sector.
- Prevention of cosmetic corrosion in automotive closure panels by control of surface activated corrosion.
- Development of self-healing and ‘smart’ coating technologies and new system assessment procedures, for example, image assisted electrochemical noise analysis to replace accelerated testing.
- Designing versatile surface treatment and finishing procedures to support the use of advanced forming and joining approaches for advanced light alloys.
- Development of targeted surface treatments for protecting welded joints between dissimilar materials.
- Surface engineering for enhanced bonding of metals in hybrid materials/ laminates and to polymer matrix composites.
- Use of more recycled material, by understanding the impact on surface engineering for in-service performance.
Examples of current projects
- A New Approach for Contrast Segmentation of Microstructural Features for 3D-Imaging and Material Characterisation
- Electrochemical Testing Coupled with Real Time Imaging, a New Tool for Assessment of Anticorrosion Performance
- Environmentally Friendly Surface Treatment for New Generation Aluminium-Litihium Aerospace Alloys
- Formation of Electroless Nickel-Boron Magnesium and AZ91D Alloy
- Impact of Shot Peening Forming on Surface Integrity of Aluminium Alloys
- Nanotomography Coupled with RF-GDOES for Evaluation of the Corrosion Performance of Processed Aluminium Alloys
- New Insights into Pore Initiation in Anodic Alumina
- Plasma Electrolytic Oxidation of Coupled Light Metals
- The Origin of Streaks on Aluminium Alloys Extrusions