THE
QUarterly Issue 9 - April 2014
journal
www.namtec.co.uk
Additive manufacture - is it a game changer? Page 14
Page 5 Reliance retains SC21 Silver Award
Page 8 The shale gas boom
Page 12 Engineering skills in the UK
The National Metals Technology Centre, University of Sheffield AMRC, Advanced Manufacturing Park, Wallis Way, Catcliffe, Rotherham, S60 5TZ
Page 18 At the cutting edge of composites
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Page 20 High Speed Rail 2
Introduction
“positive feel and a more optimistic outlook”...
Hello and welcome to the ninth edition of the Quarterly Journal. Easter is almost upon us. Just a few weeks ago, the NAMTEC team were speaking of how fast 2013 seemed to go with little let up so far in 2014. We’ve already run two successful events since our last edition (please take a look on the back cover) and have an exciting agenda planned for the rest of the year, including Manufacturing 2050 and Latest Advances in Arc Welding for Industry.
Just recently, the Commons Treasury Select Committee announced it would hold an enquiry into the availability of finance for small to medium companies. Nevertheless, when you take general manufacturing sentiment, coupled with the latest manufacturing figures, this all gives a positive feel and a more optimistic outlook, so we all look forward to continued improvement in 2014.
In speaking with our various members, I have been pleasantly surprised to hear that many of you didn’t have a quiet end of year as expected – in fact just the opposite. We have also noted an upturn in companies looking to put employees through the AMRC Training Centre's CPD courses. Of course, not all is rosy. Many smaller companies still raise concerns over access to finance.
Dr. Alan McLelland Director
Above left: Manufacturing 2050, see page 24 Left: High Speed Rail 2, see page 20 Front cover: Electron beam melt pool courtesy of Arcam, see page 14
Contents Members News
page 3-5
Case Studies
General News
page 6-7
Features The shale gas boom
Direct Company Support Scheme enhances Bifrangi’s competitiveness
page 21
page 8-11
Engineering skills in the UK
page 12-13
Introduction of a flexible 'Lean Warehouse' facility that moves with the demands of the customer
page 22
Additive manufacture - is it a game changer? page 14-17
New Members
page 23
The cutting edge of composites
page 18-19
Event Reviews
page 24
High Speed Rail 2
page 20
Upcoming Events
page 24
THE
QUarterly journal
The National Metals Technology Centre, University of Sheffield AMRC, Advanced Manufacturing Park, Wallis Way, Catcliffe, Rotherham, S60 5TZ
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The National Metals Technology Centre
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Quarterly Journal
To keep up to date with all the latest news and developments please visit the NAMTEC website at
www.namtec.co.uk
Advertising Enquiries Kirsten Bolton, Marketing Manager Tel: 0114 222 4785 Email: kirsten.bolton@namtec.co.uk
Member News
Providing heat treatment solutions for UK manufacturers AMRC Forum member BOC is part of The Linde Group, a world leading gases and engineering company operating in 100 countries worldwide. With 14 air separation units (ASUs) and a network of major production facilities, distribution centres and retail stores, BOC, the UK’s largest industrial and medical gases business, has been producing atmospheric gases, including oxygen, nitrogen and argon, for over 120 years. As companies have moved out of the recession, BOC have found they are increasingly supporting the heat treatment community within the UK. Companies are seeking to make replacements or upgrades to equipment that may have been put on hold during leaner times but, importantly, are seeing the need to make improvements to processes to meet ever more demanding heat treatment
company also has access to leading process innovations in the heat treatment industry from across the world, which it brings to the UK, thus directly benefiting local heat treaters.
specifications. Ultimately this provides increased reliability, productivity, safety, customer service and, crucially, cost effectiveness. BOC has strong relationships with a number of world-leading heat treaters in the UK and supports them on an ongoing
basis. The expertise of BOC’s engineers and their familiarity with heat treatment processes is key to the success of its work. UK clients benefit not only from an extensive local support network but also from the extended support and expertise from BOC’s global experts who are regularly within the UK. The
For the heat treatment market, BOC supplies a range of gases including nitrogen, hydrogen, argon, ammonia and a variety of bespoke mixtures. BOC’s heat treatment portfolio also includes its industry leading Carboflex range of gas equipment and control systems. With a depth of expertise and a breadth of service across the nation, BOC is well placed to support this essential metallurgical sector. For further information please contact BOC on 0800 111 333 or by email: custserv@boc.com and mention ‘Heat Treatment’
Brand new £5m facility located in Stafford
MG Sanders rebrand to MGS Precision Formed in 1971, initially as an antenna design and manufacturing company, MG Sanders are noted machinists of specialty metals and exotic alloys as well as their own in-house produced ‘Densamet’ tungsten alloy. April 2014 will see the company re-brand as “MGS Precision” and they are looking forward to a brand new £5m facility located in Stafford, which will see further investment in developing capability from being solely “build to print” machinists, into manufacturers of large diesel engine components, whilst continuing as producers of
tungsten alloy and its associated components. In terms of capability, MG Sanders have already made significant investment in 2013 with the addition of NADCAP approved NDT facilities and an aerospace components painting facility at their current factory in Stone, Staffordshire, and this will continue throughout 2015 with
MGS Precision new facilities
additional processes such as magnetic particle NDT being added to their current capability, as well as additional machining capacity. Rapid growth over the past few years has driven the company to the current expansion of capacity. However, the company is quick to recognise that E-mail: info@namtec.co.uk
sustained growth will need to be underpinned by further developments in powder metallurgy and material production, further complemented by new and innovative manufacturing processes, to support the demands of the modern aerospace, nuclear and power generation industries.
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Member News
The company which has long been recognised as one of the country’s premier industrial paint applicators for steel fabrications is currently expanding their services to provide a range of thin film coatings including Xylan, Everslik and PTFE for precision engineered components.
“When we listened to what our customers wanted, offering the greenest solution was just as important a factor as cost” said Ian Hartley - Surface Coatings Manager. “We are very pleased to be working with Chemetall and utilising their latest low temperature nickel free zinc phosphate solution to meet that market aspiration.”
The company is working in close partnership with Chemetall to create a brand new eco-friendly zinc phosphating facility opening at Easter this year.
The surface coating division are also pleased to announce that they have been
...coating new landing strips 25 years in the metal for the runways at spraying sector. Heathrow and Managing Director Gatwick. Nik Vjestica said
awarded a prestigious contract by the Marwood Group for coating new landing strips for the runways at Heathrow and Gatwick. The landing strips will be thermally sprayed with a new anti-slip alloy coating manufactured by Metallisation Limited. This new contract continues to reinforce the strong relationship between the two companies which have been working together for over
“New technology and products are important to our customers, but so are our relationships, we focus on both customers and suppliers and are committed to developing long term partnerships with them. We are convinced that this closer working approach is the way forward for British companies to compete at the international level.”
Austin Hayes: coating runway strips
Austin Hayes breaks new ground Austin Hayes Limited, the Leeds based surface coating specialist continues to break new ground by focusing on new products and technology in the metal finishing industry.
Hardide Coatings
“Drilling activity is taking place in deeper & more demanding conditions than ever before”
develops groundbreaking technology for TSP diamonds
Hardide Coatings has developed an innovative coating to extend the life and improve the performance of drilling tools operating in extremely abrasive environments. This is the first successful high performance coating for TSP (thermally stable polycrystalline) diamonds which can withstand the higher temperatures associated with TSP brazing, extreme loads and aggressive media.
extremely abrasive wear and erosive conditions such as horizontal and directional drilling, as well as fracking. Improved tool performance will enhance the viability of more challenging or marginal oil and gas reserves.
so the new coating application will reduce expensive maintenance and down time costs of drilling projects. This will in turn boost the economics of smaller and more mature oil and gas fields, such as those in the North Sea.”
Hardide Coatings CEO Philip Kirkham said: “Drilling activity is taking place in deeper and more demanding conditions than ever before and tools need protection from extreme abrasive wear and erosion that current hardfacing materials can no longer provide.
This will enable a new generation of diamond-based hardfacing materials to be deployed in
Some critical drill string components need replacement after every drilling programme,
Diamonds are notoriously difficult to attach and are prone to oxidation and graphitisation, limiting their hardfacing use to date. Previous attempts to solve these problems have been unsuccessful due to the porosity of other coatings and their weak adhesion to the diamonds. Hardide-D overcame these hurdles with its pore-free tungsten
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carbide based adhesive and protective coating which chemically bonds to diamond and has good wettability with brazing alloys. Hardide-D is the latest addition to the company’s family of tungsten carbide-based chemical vapour deposition (CVD) coatings that are deployed in extremely harsh and aggressive environments to combat severe wear issues including abrasion, erosion, corrosion, galling and fretting. They uniquely combine a range of protective properties in one material and can coat internal surfaces and complex shapes.
Member News
Reliance retains SC21 Silver Award Reliance Precision has retained its SC21 Silver Award for business excellence, having achieved the necessary delivery and quality performance levels for the second year running. There are currently just 25 organisations with the silver award, which has to be revalidated against stringent performance criteria each year to endorse that improvements have been sustained.
Andrew Wright, Reliance’s Managing Director, received the award on behalf of his team: “SC21 has provided a very practical methodology for continuous improvement right across the business. The incorporation of productivity improvement alongside quality assurance in the programme means that our continuous improvement efforts benefit both product quality and also the value that we can offer to customers. Being part of
Andrew Wright, Managing Director, receiving the award from Neil McManus, SC21
the programme continues to cement our long-term customer relationships and helps to give a strong first impression to new customers.” Andrew thanked Reliance’s customer sponsors Selex Galileo Ltd, MBDA UK Ltd and Thales Optronics Ltd for their continued support and also the SC21 leadership team for making the programme attractive to industry, stressing that its value is acknowledged not just within aerospace, defence, space and security, but across a diverse range of global markets. The award was presented by Neil McManus, the SC21 Chairman, who explained how the
programme is being taken forward to provide new auditing tools, strengthening the element of relationship excellence, expanding to cover design as well as manufacturing, and also extending geographically.
High energy picosecond pulses enables machining of thicker materials Coherent, Inc has expanded their family of industrial ultrafast lasers with the Talisker HE series, whose high energy pulses enable drilling, cutting and scribing of thicker materials than with other ultrafast lasers. Talisker HE lasers are available with a choice of output options; 200 µJ pulse energy in the near-IR (1064 nm), 120 µJ per pulse in the green (532 nm), or 40 µJ pulse energy in the ultraviolet (355 nm). Talisker HE is ideal for high-throughput, precision materials processing in industries such as automotive, biomedical, consumer electronics, mobile display & 3D semiconductor. Talisker lasers are a family of industrial picosecond products, well documented to deliver higher quality process finished goods than conventional pulsed lasers or non-laser micromachining methods. Picosecond lasers achieve the quality improvement
using a process known as ‘cold ablation’, due to negligible unwanted thermal effects. The result is improved process quality
energy of the new Talisker HE series is significantly higher than other lasers in the Talisker family. The significantly higher pulse energy extends the optical depth of the focused beam so that cold ablation occurs throughout the full
thickness of the target material, eliminating thermal debris. with minimized heat affected zone (HAZ) and no unwanted melt debris. Cold ablation occurs when the intensity of the laser beam exceeds the ablation threshold. The pulse
The higher energy pulses are used in a variety of materials processing techniques. Single shot pulses replace percussively drilled holes, meaning that very thick materials are drilled with reduced taper and engraving and trepanning benefit E-mail: info@namtec.co.uk
from deeper, high aspect ratio structuring. The Talisker HE distinguishes itself with superior pointing stability. Pointing stability is critical to drilling thick materials where the pulses must be directed to the target with dependable accuracy. The maximum material thickness is ultimately limited by a combination of the laser pulse energy and the pointing stability. Founded in 1966, Coherent, Inc. is a world leader in providing photonics based solutions to the commercial and scientific research markets, and is part of the Standard & Poor’s SmallCap 600 Index and the Russell 2000. www.Coherent.com. Image: Coherent Talisker HE series laser
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General News
Capital contract is just the ticket for Mechan
Thameslink-bogie Mechan
Sheffield manufacturer, Mechan, is enjoying a boost in sales after securing work worth more than £1 million from landmark UK rail project, Thameslink. The depot maintenance equipment specialist will be providing four bogie drops to two new facilities being constructed as part of this historic upgrade to London’s transport network. Commissioned by Siemens Rail Systems UK, the first two bogie drops are under construction and will be installed by Mechan at the Hornsey depot in April 2014. Based in the London borough of Haringey, this three-road, 12-car maintenance facility will sit alongside the East Coast Mainline and is set to be completed in 2016.
lifting or splitting the carriages. Richard Carr, Mechan’s Managing Director, said: “We have proved that our bogie drops are at the forefront of depot technology and that their build quality offers unrivalled reliability. Receiving such a significant new order from a valued repeat customer is hugely gratifying and we are pleased to be contributing to Thameslink, one of the most ambitious and comprehensive updates to the capital’s rail system in recent years.”
“build quality offers unrivalled reliability”
A further two bogie drops will be delivered to Crawley’s Three Bridges depot in September. This entirely new facility is larger than its counterpart in Haringey, containing five roads, split across two sites on either side of the London to Brighton mainline. In both locations, the bogie drops will be used to service the new Desiro City trains, entering service early in 2016. Mechan’s equipment is installed in a pit within the depot floor, enabling bogies and undercar modules to be removed or exchanged without
Prior to securing this contract, Mechan has supplied Siemens with five bogie drops in the past seven years, for depots in Southampton, Northampton, Manchester and Scotland. During this period, the firms have collaborated to modify the design, including a raised floor that covers the pit when the bogie has been removed, maximising workspace in maintenance facilities. For further information about Mechan’s bogie drops and its wide range of depot maintenance equipment, telephone (0114) 257 0563 or visit www.mechan.co.uk
Dyson & Imperial College invest in robotics... James Dyson is set to invest £5 million in a new robotics centre at Imperial College, London. The centre will recruit up to 15 engineers and scientists to develop vision systems to extend the autonomous application of robots. Vision input will help move robots from working in closely defined environments to one where they can adapt to their
Sir James Dyson
surroundings. Robotic vacuum cleaners are a known ambition of Dyson. The investment comes at a time when such companies as Google, Amazon and Microsoft are all investing heavily in artificial intelligence (AI) and robotics. Recently Google has acquired no less than eight robotic related companies and has spent a cool £400 million on DeepMind Technologies, a London based start-up focused on AI.
Drax goes green Drax is set to become the largest single renewable electricity generator in the UK as it progresses with a move from coal to renewable biomass fuels sources at the Drax power station. The station, responsible for around 7-8% of the UK electricity demand, announced plans to convert three of its six burners from coal to biomass in 2012. The first unit was converted in April 2013 with the second planned for 2014 and the third in 2016. Drax uses only sustainable biomass from
sustainable forestry and forestry residues, residual agricultural products such as straw, sunflower seed husks, peanut husks and purpose grown energy crops. The company has calculated that the change to biomass reduced carbon emissions by around 80% compared to coal.
1000 new jobs to be created after Green Port Hull is confirmed Manufacturing company Siemens has confirmed it is to build major wind turbine production and installation facilities on the banks of the Humber, investing £160m and creating 1,000 new jobs. An artist's impression of the Siemens proposed offshore wind project construction assembly and service facility at Green Port Hull. Photograph: Siemens/PA
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The German company has revised its plans, doubling the investment and increasing the jobs created, giving a
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boost to the offshore wind industry in the UK. It has taken until now for a deal to be signed between Siemens and its port partner, Associated British Ports (ABP), which is investing a further £150m in the Green Port Hull development. Siemens said it will be the first manufacturing plant of its kind for its next-generation blade technology
designed for wind turbines. ABP chief executive James Cooper said: “The announcement by Siemens today underlines the critical role the Humber region plays in servicing the UK’s energy needs, both today and in the future. We are delighted that Siemens has chosen to partner with us to realise this exciting project.”
General News
Asia’s biggest airshow takes off The Singapore Airshow in February is seen by all of the major aerospace companies as a key window into the important Asia-Pacific market.
Currently this region accounts for 35% of world demand, with Airbus predicting it will require around 10,000 new aircraft by 2032 and Boeing suggesting the market is worth some $1.9
billion over the next two decades. Airbus took the opportunity to showcase the new A350 extra wide body (XWB) aircraft with its maiden public flight. Unconventionally,
rather than a plush interior, the maker chose to fill the aircraft with banks of data monitoring equipment, fed with over 400km of cables, demonstrating the lengths they go to in developing
new aircraft. During the show, Airbus confirmed orders for 20 A380 aircraft worth £5 billion for Amedeo and an order for up to 100 A320 aircraft for low cost Vietnamese carrier VietJetAir.
New venture for Tata Motors Ltd Boosting the supply chain Lord Kumar Bhattacharyya KB CBE, Chairman of WMG & Nick Fell, Director of TMETC
Tata Motors Limited has confirmed it will invest in the new National Automotive Innovation Campus (NAIC). Through its subsidiary, Tata Motors European Technical Centre (TMETC), Tata will invest £30 million in the £100 million venture together with partners Jaguar LandRover and Warwick Manufacturing Group (WMG).
The facility, to be built on the University of Warwick campus starting September 2014, is supported by the Higher Education Funding Council England (HEFCE). The centre will create new technologies that will stimulate the automotive industry with a focus on reducing dependency on fossil fuels and reducing carbon emissions.
The Aerospace Growth Partnership (AGP) is a collaboration between industry and the government which sets out a long term commitment to investing, maintaining and growing the UK’s position as the second largest aerospace economy. government. Aimed at small and medium companies, NATEP helps them develop technology with a programme target of maturing 100 technologies and creating jobs in the supply chain. One of the initiatives of the AGP Companies apply through a has been to establish the series of calls and are supported National Aerospace Technology by both regional and national Programme (NATEP), taking a representatives in the working model proven by the Midlands Aerospace Alliance and construction of their applications. extending this on a national basis Further details can be found via with £23m funding from www.natep.org.uk Leading their activities through a series of working groups, the AGP addresses challenges in technology, manufacturing, supply chain and skills.
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Features
The shale “USA gas price is now a quarter of that in Europe�
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Features
gas boom Recently, there has been a lot of news surrounding UK shale gas. Seen as a secure national source of low cost gas, the potential impacts of shale gas recovery, on both the environment and public health have also been loudly voiced.
Shale gas exploration sites
In simple terms, shale gas is a natural gas, predominantly methane, found in shale rock formations. Shale gas differs from the more conventional gas sources as the shale rock is impermeable and requires hydraulic fracturing, or fracking, to break the rock and unlock the stored gas deposits. It is only in the past decade that shale gas has become economically viable with most development having taken place in the US. This has led to a falling gas price, now a quarter of that in Europe, and it is argued a reduction on CO2 emissions as it is cleaner than the coal it is replacing. However, the reduced US demand for its coal has led to substantial exports into Europe and, while beneficial in terms of cost, it has raised concerns over increased EU carbon emissions.
feet in the north of England alone, although it is not known what proportion of this can be economically recovered. With such a significant volume, shale gas is seen as a key energy resource, potentially reducing energy costs and dependency on imported gas.
The UK has seen some important moves in this arena. Cuadrilla, 25% owned by British Gas’ parent company Centrica, has been the most proactive, with a number of exploratory drilling activities most notably in the Estimates of shale gas volumes North West of England. In vary considerably. Globally, preliminary studies estimate 456 January of this year, the French trillion cubic metres of gas, of owned oil giant Total announced which some 40% is economically it was investing at least $21m recoverable. Around 7% of this is (£12.7m) in UK shale gas exploration. UK Energy Minister within the EU, with significant Michael Fallon has been quoted reserves in Lithuania, Poland, Romania and Ukraine. The British as saying he expects up to 40 Geological Survey has indicated shale gas sites to be drilled in England over the next two years. reserves of 1,300 trillion cubic Cuadrilla shale gas site
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Features Total drilling rig
However, UK exploitation is not without challenge. In the US, shale gas reserves are generally large and accessed from multiple locations, this may pose problems in the UK due to the much higher population density. It has also been argued that opposition to fracking in the US has been diluted due to the financial benefits reaped by local residents – this will not be the case in the UK where mineral reserves are owned by the Crown Estate. Many opponents to shale gas extraction in the UK have raised significant environmental and public health concerns, often referring to evidence from the US. The most public of these has been the potential of seismic events – in the North West of England drilling by Cuadrilla was stopped due to two earthquakes, the cause being attributed to direct injection into a fault line. Cuadrilla point out that the British Geological Society website details nine events of a similar magnitude in a two month
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period. While experts cannot rule out future events, the belief is these would remain low in magnitude and the risk low. It is however likely that any licence would require measurements of seismic activity with a maximum permitted level. Fracking uses large quantities of water which is pumped into the well and back up. The returning water is contaminated by the fracking additives, sand, rock, and by naturally occurring radioactive material. In the US a considerable industry has grown up around the need to treat the water so that it may be reused. Less well discussed are the concerns over potential contamination of the water table, through which drilling would pass, due to fracking fluids or methane gas entering the water table, either through inadvertent direct penetration into the water table or leakage on return of the fracking fluid to the surface. There is evidence of water contamination within the US but these have been largely
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apportioned to poor well management. Few companies actually publically declare what is in their fracking fluids due to commercial sensitivity, although one notable exception is Cuadrilla. Of course, the main opposition to shale gas comes about not as a result of the process, but from the continued use of the CO2 generating gas when employed in energy generation. While cleaner than coal, the argument is that it maintains, and even Shale gas extraction
“opponents to shale gas extraction in the UK have raised significant environmental and public health concerns” increases our dependency on fossil fuel, reduces the incentive for the development and implementation of renewable energy sources and could set the world back in its quest to reduce greenhouse gas emissions.
Features Shale gas drilling rig operated by Cuadrilla
Fracking
Manufacturing Potential Studies by the Royal Society and the Royal Academy of Engineering have both given a positive view towards shale gas extraction, but under strictly controlled conditions to ensure environmental and human impacts are properly considered and managed. The immediate future will see greater clarity of the true potential for shale gas in the UK, in terms of realisable volumes, costs and scale of implementation. Techniques, components and systems used for shale gas are expected to differ little from that conventionally used in the oil and gas industry - the key techniques of horizontal drilling and hydraulic fracturing (fracking) are long established in the sector.
Cuadrilla shale gas site
Nevertheless, the potential scale of shale gas within the UK, and in our close neighbours within Europe, will create a significant increased demand for the necessary equipment. The strength of the UK in manufacturing for the oil and gas sector will stand it in good stead to exploit this growth. One should also not neglect associated benefits – this new production scene will require pipeline, tankers, distribution centres, terminals and storage facilities to allow the extracted gas to find its way to our power stations and homes.
“With a current government supportive to this initiative, one is hopeful of seeing real benefit being created for the UK”
Hydraulic Fracturing, or as it is more commonly referred to, fracking, is a process whereby a mixture of water, sand and chemicals are injected into shale rock under pressure to cause opening of fissures in the shale rock and release of the gas entrapped within it.
The pressure exerted by the fluid, referred to as ‘slickwater’ opens these small fissures, some as small as 1mm across, and then tiny grains of ‘proppants’ hold the fissures open so that the gas can be flushed out and drawn to the surface and recovered. For shale gas, the technique also relies on the technology of horizontal drilling. Rather than simply drilling vertically downwards, the drill head is turned and then steered outwards in the horizontal plane, often in many directions and at distances of many miles, to maximise access to the shale rock and its precious reserves.
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Features
Engineering
skills in the UK
The UK needs more engineers. One could argue this hardly needs reinforcement but a recent report by Professor John Perkins at the Department for Business Innovation and Skills (BIS), entitled ‘Review of Engineering Skills’, lays out “between the case in clear terms with a real call to action. Engineering drives technology change throughout our economy, not just in manufacturing. While future demand is difficult to predict, the Royal Academy of Engineering (RAE) forecasts that between 2012 and 2020, the UK will need some 830,000 scientists and engineers to fill new roles and those vacated by an imminently retiring workforce. That equates to some 100,000 a year – where are they going to come from? Currently the UK is supported by overseas engineering staff that make up around 20% of the demand. While this is hugely beneficial and brings a positive diversity to addressing the engineering challenge, it is recognised that this is not a long term solution – this has to come from our own national activity. However, this is neither easy nor quick. The future pipeline needs to be primed from an early age and the young shown the breadth and potential that such a career path offers. However, we also need to educate the parents and teachers who have such a strong influence on young people’s futures. We should also not neglect the female population who today are terribly under-represented within the mix.
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Having engaged young people, one of the challenges is then to maintain that interest and here some of the statistics are especially worrying - engineering demands mathematical aptitude, but only 20% of students in England study maths past GCSE compared to 48% in Scotland, 65% in the USA and a staggering 90%+ in Germany. Roughly half the adult population of England has a maths skill equivalent to that of a 10 year old and current 16 to 24 year olds have a lower proficiency in maths than their grandparents. No-one can underestimate the starkness of the challenge. Fortunately, a lot is being done to turn the tide. There are a wealth of activities aimed at engagement of young people, although the Perkins’ report suggests this is poorly coordinated, and so we see efforts by the RAE and Engineering UK to coordinate and maximise the impact. The government is placing a new focus onto mathematics, both improving the curriculum and seeing the subject continue through to age 18. In 2016 more rigorous science and computer science GCSEs will be introduced and A-levels reformed to give universities
2012 and 2020, the UK will need some 830,000 scientists and engineers to fill new roles” greater say on their content to ensure a better grounding for higher education. Especially pleasing has been the resurgence in the apprenticeship. The Engineering Employers Federation (EEF) reports that in engineering and manufacturing technologies new starts in 2012/13 reached over 66,000, which was 13% of all new apprentice starts. These schemes come with much greater levels of employer engagement, helping to ensure their needs are met. Nevertheless, more needs to be done in this area, with employers remaining concerned about the pace of change in technology which needs to be reflected in the content and in the availability of specialist training provision.
Features
Engineering skills - group learning
However, even with an increasing graduate complement, retention within engineering remains a major challenge. As many of our readers will know, the qualities that create a good engineer – problem solving, being mathematically astute, inventiveness - are the very same as desired by other nonengineering disciplines such as finance. Today, only about 70% Engineering is a great career choice for both men & women of male engineers remain in their field three years after graduation and only half of female graduates even enter the field. Somewhat at odds with a seemingly strong demand, we still have a significant portion of engineering graduates who are unemployed, notably in the electrical and electronic engineering field.
Machining apprentice
Higher education remains the most common route into engineering and refreshingly, intake numbers are increasing – up some 20% in 2012 compared to the last 7 years – although some engineering disciplines, such as electrical and electronics are falling. The situation is also being complicated by some institutions reducing engineering courses and increased availability within other institutions being insufficient to meet demand.
This is no easy challenge, with little chance of easy answers or a quick fix. The Perkins’ report makes some clear and stretching recommendations to government and to industry. Some initiatives are underway and they start to provide benefits, but this is a long term investment, one we can ill afford to take our eye off.
Bosses go back to the floor for National Apprenticeship Week To mark National Apprenticeship Week 2014, the AMRC Training Centre invited senior managers from local manufacturing employers – all of whom currently have apprentices at the Training Centre – to go back to the floor and spend a day as an apprentice.
Production and HR Director James Selka of AESSeal, who also started his own career as an apprentice, was impressed with the AMRC Training Centre Facilities. “This is streets ahead of what we had,” he said. “Everyone's engaged, and they seem much more mature than we were. It's really well run and the people here want to learn, and they are being stretched.”
The bosses were given an apprentice to look after them, and a simple machining or welding task to complete under close supervision. For many, it was a return to the earliest days of their own careers – and a chance to see how apprentice training has changed over the past decades. Participants came from many companies including Tata Steel, Darron SBO, Tinsley Bridge, MTL Group, Newburgh Engineering; AESSeal, Evenort and Helix Tools – plus the Training Centre’s own Director Alison Bettac.
James Selka, Production and HR Director, AESSeal
Alison Bettac said that the day showed everyone the value of the new Training Centre. “I've learned what high standards our apprentices have within the centre – we weren't here to do a slapdash job, and if we did, we were picked up on it,” she said. “We all found that our apprentices are far in advance of what we thought they were going to be. The support we've had from them was of a very high standard. They've given everyone a real feel for the ethos and philosophy of the centre.” If you are thinking about taking on an apprentice please visit amrctraining.co.uk
Back to the floor - all bosses pass their first day E-mail: info@namtec.co.uk
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Features
Additive man Medical implant
- is it a game changer?
Titanium alloy F1 heat shield manufactured by the Mercury Centre using electron beam melting
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“AM production and services grew by 21% in 2012 to over $2 billion, with forecasts set to double by 2015 & treble by 2017.�
Features
nufacture It seems everyone is talking about additive
manufacture (AM). Even the President of the United States, in his 2013 State of the Union speech, described it as having the potential to revolutionise the way we make things. This is not a new technology, but it is seeing a significant resurgence in interest, partly driven by the expiry of a number of patents but also from a drive to exploit the unique capabilities of the process.
Electron Beam Melt Pool courtesy of Arcam
Often described as a ‘disruptive’ technology as it changes the way we do things, AM is equally seen as enabling - it creates a whole new manufacturing genre, with new design thinking and a totally new supply chain; one which may not include the current incumbents.
This film car was made made by Audi with rapid prototyping industrial KUKA robots
A DMLS - made gas turbine prototype swirler in cobalt chrome. (Courtesy Morris Technologies)
In May 2013, the Royal Academy of Engineering (RAE) drew representatives from across the AM domain to examine the current state of the art and lay out the future challenges. The RAE reports that AM production and services grew by 21% in 2012 to over $2 billion, with forecasts set to double by 2015 and treble by 2017. One of the most significant milestones in AM has been the relatively recent use of AM technologies to manufacture components for series production application. The activity has risen from virtually zero, to around 27% of AM activity in under 10 years with some notable recent announcements. These include an investment by GE of some
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tens of millions of dollars which included the purchase of two companies. GE plan to use the technology to manufacture fuel nozzles for its latest generation of aircraft engines, with production targeted for late 2015. In addition, BAE Systems has revealed that AM parts have been flown on Tornado jet fighters, opening the path for future mainstream application. While many of the developments are being led by the aerospace sector, the technology is equally applicable and thriving in other sectors such as automotive, consumer goods and also in biomedical, where the potential for bespoke medical implants is a close reality. As a unique process, AM offers up a different manufacturing envelope – no longer do we need to think in a subtractive manner. Design constraints are almost removed with the mantra ‘if you can imagine it, we can make it.’ However it is more than just how parts might look – it allows an unprecedented ability to optimise designs, removing material where it is not
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Titanium turbine blade manufactured by selective laser melting
3T RPD's metal AM facility
needed, using carefully engineered structures to impart strength and stiffness and with minimal material having to be added simply to allow the part to be manufactured. It lends itself to both low and high volume production, to a reduction in material waste, and a faster time to first products, to working wholly in the digital domain, moving from CAD to part is possible, and easy design changes can be made during a product’s life. The supply change is both shorter and much less complex.
a complete shift in approach to take maximum advantage of the advantages that the process can offer. While the UK has some strength in this area, a recent Technology Strategy Board initiative suggested that the UK was not leading in any particular area of AM. We are however home to significant players such as Renishaw and 3T RPD, to development activities within
Airbus and GKN and to research clusters such as Nottingham and Sheffield University. Recently the government announced funding for the Manufacturing Technology Centre's creation of a National Additive Manufacture Centre. This and other initiatives within the Catapult Centres, and beyond give the UK an excellent standing in exploiting this game-changing manufacturing technology.
What’s in a name? Additive manufacturing (AM) is an umbrella for a wide range of manufacturing technologies which create components in an incremental manner – adding to create the final form. Other terms often used include additive layer manufacturing (ALM), 3D printing, and rapid prototyping. There are a whole variety of techniques applicable to metals, polymers and even ceramics, with the potential to create representative shapes for fit and form, to manufacture first off prototypes for testing, through to full scale mass production qualified parts.
However, work still remains to be done. Powder metal is an expensive raw material and there is currently a limited supply chain, especially for the cleanest grades in the more challenging alloys. Manufacturing rates per component remain too low and experts suggest they need to increase by up to a factor of ten. Process control is a key issue because of the management of a several hundred parameters, and related to this is the issue of reliability of product performance. An absence of internationally recognised standards is now being actively addressed with a joint US – Europe initiative. Aside from the physical attributes, perhaps one of the greatest challenges will be around the education of designers – the process requires
Some of the more commonly noted processes include stereolithography (polymerisation of plastics using light), selective laser sintering (fusing metal or polymeric powders) and electron beam melting (fusing metal powder or wire).
1. Automotive intake manifold prototype manufactured using stereolithography 2. Image showing construction of the Tornado 3D-printed parts 3. 3T RPD made the titanium lattice for the Queen's Commonwealth Games baton using metal AM technology 4. An EOSINT DMLS system laser-sintering cobalt-chrome dental copings and bridges in a batch (Courtesy EOS) 5. Close up showing construction of the Tornado 3D-printed parts 6. Largest 3D printed part produced in the UK - BAE Systems generic wing spar section 7. A laser-sintered drill guide designed to conform to the patients bone geometry (Courtesy Materialise) 8. Complex designs are an AM advantage (Courtesy EOS) 9. Acetabular cup (hip implant) made using electron beam melting E-mail: info@namtec.co.uk
Renishaw AM250 Laser Melting System
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Features
At the
by Dr Betime Nuhiji and Dr Kevin Kerrigan
cutting edge of
composites
Machining is a destructive operation, not only to the material itself but also the tools used. Although carbon fibre reinforced polymer (CFRP) materials can be moulded to near net shaped components, there is still a requirement for post-process machining, mainly for high value added parts. However, the procedure of machining composites differs to that of metals. Metals are commonly isotropic (similar in all directions) due to their homogeneous nature, while CFRP materials are heterogeneous, whereby their properties are anisotropic (of unequal physical properties along different axes). Given the complexity and variation in these materials (fibre orientation, fibre and resin selection, curing methodologies), composites are difficult to machine and present new challenges.
chemical debonding, fibre pull-out and fraying as well as thermal degradation of the resin matrix. The tooling itself could also experience rapid wear in the form of initial cutting edge rounding and flank wear. While industry is pushing for higher throughput and higher feed rates, the importance of selecting the correct parameters for a CFRP machining operation is crucial, as several factors can influence the qualitative and quantitative damage inflicted. Factors include fibre orientation to the cutting tool, tool acuity, cutting speed, feed rate, depth of cut as well as thermo-mechanical properties of the composite.
Extreme thermal damage due to incorrect parameter selection.
A number of damage mechanisms can arise when machining CFRP materials via means of traditional metal machining techniques. Drilling, milling/trimming and turning mechanisms can induce damages to the composite material, such as interplay and intraply delamination,
The effects when drilling of carbon fibre reinforced plastic composites.
Following a fundamental understanding of the chip formation mechanisms of composite materials, two machining techniques have been investigated throughout this article; hole generation and edge trimming. These techniques are the most common shape generation processes currently being utilised to machine CFRP materials. In a conventional metal machining process, the interaction between tool and workpiece results in the generation of a shear plane on the workpiece. The chip formed in metal machining operations such as drilling, typically result in long, continuous helical chips which ‘flow’ from the cutting zone. Unlike metals, CFRP material properties vary (i.e. high strength brittle fibres and low strength binding matrix), and in turn no shear plane is generated. Instead, the composite fractures in a brittle manner to form dust-like particles in the order of 1 m to 100 m, depending on the material and machining parameters selected. Given the size of these particles, care must be taken and the appropriate safety regulations must be in place to handle these dust-like chips. In addition, these abrasive particles are required to be removed from the cutting zone and tool face as quickly as possible, as they can damage both the tool and machine. To maintain the tool and machine health
during the composite machining operation, an extraction system is used in dry operations, or high volumetric flow rate of coolant is incorporated into the process in ‘wet’ operations. Developments in the cutting tool design have led to the use of harder materials. Such material advancements include diamond films, which can be coated via chemical vapour deposition (CVD) or polycrystalline diamond (PCD) inserts, which can be brazed to a substrate (typically tungsten carbide). The diamond is used to improve machining performance, increase the lifespan of the tool as well as enhance the surface finish of the workpiece.
Drilling tools. Coutesy of Sandvik Coromant.
Milling / trimming tools.
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Wear
Wear.
Advanced 3D tool wear inspection techniques.
Features Composite machining
“composites are difficult to machine and present new challenges”
New Tool
Worn Tool
shows strong potential to address this, with commercial machine tools now entering the market which may solve the low feed rate challenge of composite machining. In UAM technology, a piezoelectric crystal is fitted into a conventional spindle and a charge applied to this crystal. Due to the piezoelectric effect, the result is a high frequency, low amplitude oscillation of the spindle in the orientation determined by the crystal. When applied to CFRP machining applications, this UAM technique has seen increases in feed rate of up to ~8 m/min – 20m/min in trimming applications, with minimal loss of tool life or surface quality.
Hole generation
Hole quality challenges.
Alongside the difference in chip formation to metals, composites also differ in terms of their sensitivity to high temperatures. When exposed to machining tools, composites have a tendency to heat quickly, as does the tool itself. Yet industries are searching for technologies that can generate higher throughputs that increase the feed rate and throughput capabilities in the removal of composite materials. Ultrasonic assisted machining (UAM)
Although many technologies such as laser ablation, electric discharge machining (EDM) and abrasive water jetting have been investigated as potential solutions for hole generation in composites, the primary methods used in industry remain CNC machining and manual drilling. The latest technology to support this involves the use of 5-axis milling operations, which ensure highly precise and concentric motions of the drill as it gradually moves through the
composite material to the final hole dimensions. The reduced load during the cutting operation can provide both increased tool life and higher hole quality. Given that a typical aircraft structure can have anywhere from 10,000 to 50,000 holes, it is vital for the aerospace industry to select not only the correct tool material and geometry, but also the most appropriate strategy for hole generation.
Edge trimming (peripheral milling) One of the major difficulties of trimming the outer surface of a composite is relaying to the machine tool where the excess waste material ends and the actual part begins. With developments in software designed to communicate with the controller of a machine tool, not only is location of a composite part on the machine tool possible, but also realignment of the machine tool to these parts. Such software ensures that tight tolerances are met with the option of additional correction machining passes, based on probe information assessed by the software. An additional area being explored in relation to the trimming operation includes the effect of composite workpiece material variations
on machinability. Both thermoset and thermoplastic resins have been investigated by the AMRC as well as carbon and glass fibres. Results indicated that the type of composite used can have a significant impact on the forces, tool wear, chip formation and surface quality achieved for a basic edge trimming operation. The AMRC in conjunction with Sandvik, OSG, Technicut, Walter and Seco, are investigating cutting technologies that reduce the wear of cutting tools and damage of composite materials. A number of CFRP composite specific machining research activities include; • Composite / metallic stack drilling investigations for aerospace applications • Surface quality assessment techniques for composite machined surfaces • Effect of CFRP mechanical properties when exposed to wet (flood coolant) vs dry composite drilling The AMRC will be holding an event on the 17th September, to discuss how composite materials can be introduced into various industries. For more information on this and composite machining, please email chloe.lidster@namtec.co.uk
Hole drilling
Hole generation machine
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Features
High Speed Rail 2 When first built, the UK rail infrastructure was never really designed for interconnectivity. Implemented by a series of individual companies, they were clearly not keen to have their passengers moving to a competitor as part of a journey. Roll forward, and our drive for an interconnected rails system is very much different. Seen to have had positive impacts in other countries, the adoption of a second high speed rail network (the so called HS2) in the UK will link the major cities of the Midlands and the North to the European network through London and the Channel Tunnel. Phase one will link Birmingham and phase two will extend this link to Manchester, with a major new station to be constructed at Sheffield Meadowhall.
upgraded and substantial new track laid to meet the higher speed demands, all with the associated signalling and management systems. Large portions of the track will be lowered to help reduce noise and impact on residential areas. Stations will need to be constructed and extended to cope with much longer train lengths and, of course, there will be the trains themselves. In November 2013, the first HS2 Supply Chain Conference was attended by over 600 companies. Here the Outline Procurement Strategy was presented prior to full roll out in the next conference due in summer 2014.
The engineering required is considerable. Existing track will need to be
Bombardier
ket? your tic d e k o u bo Have yo s the train... is cts Don’t m ing proje r e e in g ive en ities > Mass pportun o l ia t n e pot > Huge
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Map showing planned route for HS2.
Further information will be available through the HS2 website – www.hs2.org.uk
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In related rail news, Bombardier has been awarded the contract to build 65 new trains for the London Crossrail project. Worth
up to £1 billion, the work helps secure 1600 manufacturing jobs at the company’s site in Derby.
Case Study
Case study
Direct Company Support Scheme enhances Bifrangi’s competitiveness Bifrangi UK are an advanced manufacturing company providing a range of high end products into the automotive and power generation sectors. Its client base includes both Prime and Tier 1 suppliers and includes leading organisations such as Perkins, Daimler, Cummins, Iveco, New Holland and Guascor. Whilst quality management has always been paramount in the business and appropriate procedures and processes were in place, the company is continually improving in response to the increasing requirements of the automotive sector, which can be specific and challenging. In the previous year the company had undergone a reorganisation to better position itself to capitalise on future opportunities, focusing on some significant growth targets. As part of their ambitious growth plans, the company placed an increased focus onto technology developments, which had always been a key differentiator for the company’s products. In addition, Bifrangi was also seeking to streamline and reinforce its working procedures and processes, further enhancing their customer focused thinking and especially to strengthen their ability to rapidly and confidently
“Overall the project to date has improved our competitiveness and will place us in a stronger position Mark Alcock, to win new Technical Manager, Bifrangi business.”
pinpoint root causes of often complex engineering problems. With financial support from the ERDF funded Direct Company Support programme operated by NAMTEC, Bifrangi selected Brook Corporate Developments
to work with them in bringing about these significant enhancements. Using well established structured analysis techniques, Brook Corporate Developments undertook a detailed analysis of the company’s procedures, helping define improvements and bringing about a significant reduction in overheads and lost productivity. Using these enhancements, the improved processes were then proven by implementing them against four projects to improve
productivity and quality in the manufacture of crankshafts: • Reduction in distortion to help minimise straightening, post hardening, reduce scrap due to straightening cracks, elimination of a re-centring operation and to present a better crank for grinding. • Reductions in thermal cracking. • Improvements in surface finish techniques with the potential for marked performance enhancement.
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• Scrap reduction within the induction hardening process. The overall programme of support has yielded immediate cost savings, with the internal projects presenting an estimated benefit of up to £100,000 per year, with much greater potential in the future as the knowledge gained is cascaded throughout the company. Unquestionably, the demonstration and support of the application of the enhanced processes on tangible projects also cemented the knowledge transfer into the company.
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Case Study
Case study
Introduction of a flexible ‘Lean Warehouse’ facility that moves with the demands of the customer Mailway, based in Bradford, are a leading packaging company using a range of advanced and highly automated solutions across a wide variety of packaging challenges.
With a strong senior management team, one of the key strategic requirements of their business plan was further sustainable growth, which required a strengthening of their warehouse efficiencies. This would allow the business to react to customer needs, and the growing demands of each market sector, without further expansion of facilities. With such a demanding goal, the company sought external assistance to allow an optimum solution to be implemented in the shortest time frame and with minimal disruption to current operations. With technical and financial support from the NAMTEC Direct Company Support Scheme, the company engaged the services of framework provide Director Resources who had the desired expertise in application of ‘Lean Warehouse’ principles.
Jointly, the company, supported by Director Resource then embarked upon a business improvement programme to define and implement lean techniques into the warehouse function. The result was a transformed warehousing system that delivered ‘First In First Out’ and visualisation of each individual pallet location. It also allowed for product type / category segregation, which could be managed against customer / market demands.
Over a short and intensive experience, Paul Cook, an expert from Director Resource, reviewed the current warehouse solution which was based on a ‘First In Last Out’ principle, identifying the major parameters, analysing the daily movements of stock and forklifts and where bottlenecks in the current warehouse management system were appearing.
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Production line
activities, and is now well placed The result has been an increase to sustain current gains and in stock utilisation of 15% along bring about a renewed focus with a 40% improvement in the towards continuous efficient use of forklift improvement. movements. Critically, this allowed the company to further Richard Bramma grow its business without a need - CEO for further warehouse space – “Optimising the increasing turnover and warehouse has existing maximising profits. In addition, through the implementation of the lean tools, the company has been able to identify further non-value added
substantially contributed to Mailway’s ability to sustain a growth of over 113% in the last year while ensuring their efficiency and customer focus were not impacted by the increased inventory and stock movements”
Richard Bramma, CEO
Quarterly Journal
New Members
New members Bromford Industries Bromford Industries is a privately owned enterprise trading on a global basis, supplying precision machined components, fabrications and assemblies to leading OEMs in the aerospace, defence, marine, power generation and nuclear markets. Operating from facilities in the UK, the company specialises in fully integrated solutions utilising core competencies including: complex machining and fabrication of super alloys; supply chain management expertise; specialist finishes and assemblies, all fully integrated and supplied to customers’ requirements. Bromford Industries supply diverse and highly engineered solutions to provide their customers with a competitive edge through lowest total cost of acquisition, from a single source supply point and a high level of integration through assembly packages.
As the preferred supplier to many of Europe’s leading manufacturers, Chapmans now have representatives based in France, Poland, Germany, Spain and Italy, supporting their manufacturing headquarters in Sheffield. www.chapmans-uk.com
Coherent (UK)
With superior reliability and performance as its founding principal, Coherent offers a unique and distinct laser product portfolio that touches many different markets and industries, giving its commercial and scientific customers a decided advantage as they seek breakthroughs in the development of cutting-edge applications.
Chapmans Ltd
Since its beginnings in 1966, Coherent has been designing, manufacturing and marketing laser sources, laser tools, and laser systems to users in both the commercial/industrial space as well as those within the scientific research market.
Chapmans utilise their vast experience combined with engineering know-how and investment in innovative processes, back by exacting quality control, to manufacture agricultural wear parts of exceptional durability.
Within the commercial/industrial arena, they continue to facilitate the rapid adoption of photonics tools. Enabling their customers to evolve from one or more discrete technologies to fully integrated solutions reinforces their commitment to drive innovation and selection through a broader spectrum of technologies and capabilities.
www.bromfordindustries.co.uk
Chapmans primarily operate in the key sectors of: plough, sub soil and deep cultivation, slurry and waste spreading, grassland management, planting and light cultivation and root crop harvesting. A commitment to quality is the cornerstone and driving force behind their business. By sourcing the highest quality steel grades and retaining full control of the heat treatment process, Chapmans are able to push the boundaries of durability and produce extremely robust components with optimum hardness and extended wear life. Rigorous finishing processes result in a product that is a benchmark for industry.
Coherent has always placed tremendous importance on meeting the needs of the scientific laser community. Helping customers remain at the forefront of scientific research is the cornerstone of their strategy in the scientific market. They continue to strengthen this strategy, pooling key resources that allows for as fast product development as possible. www.coherent.com
HBM nCode nCode products are provided by HBM, a world-wide technology and market leader, offering products and services across the entire measurement spectrum, from virtual to physical. For over 30 years, nCode has been the leading brand for fatigue and durability solutions for both test data applications and FEA fatigue analysis. Its technologies enable engineers to understand product performance, accelerate product development and improve design. The power and ease of use of nCode technologies is a direct result of its world-class development process, expertise and in-depth experience of a broad range of industries. Reliable product support and training is provided by in-house experts through HBM-nCode offices in Europe, North America and Asia. www.ncode.com
Lidsters Paragon Tool Co. Lidsters is a company committed to meeting the needs of their customers by manufacturing the finest quality HSS drill bits in the most timely and cost effective way possible. The company has its origins in the manufacture of special HSS drill bits and has grown to incorporate the economic production of larger volume products whilst still adding to its specials capability with modern CNC machinery. For over 50 years, this privately owned business has driven forward by investment in new equipment and by a desire for constant improvement. From their humble beginnings Lidsters is now the largest manufacturer of HSS drill bits in the UK. Operating from their purpose built manufacturing centre in Sheffield England, Lidsters drill bit manufacturers have built an international reputation for service, quality and value in the HSS drill bit market.
Thompson Friction Welding Thompson is an awardwinning manufacturer of a renowned range of rotary and linear friction welding machines and supplier of associated automated production systems. Thompson machines are designed to join a wide variety of parts, from small diameter components such as air bag canisters, engine valves and pump shafts, to large diameter components including API drill pipes, track rollers and trailer axle tubes. The company also operates probably Europe's largest sub-contract friction welding facility at its site in Halesowen. Thompson machines are used by the world's top component makers to join a wide range of parts used in airplanes, cars, construction machines, tractors and trucks, as well as for mining and mineral exploration equipment. It holds a Queen's Award for Enterprise (International Trade) and Boeing Performance Excellence Award. www.thompson-frictionwelding.co.uk
MGS Precision MGS precision are a precision manufacturing company operating from a 7,000 m² hi-tech manufacturing facility ideally located in Central England. Established in 1971, as MG Sanders, they have earned an excellent reputation for process innovation, production and delivery of high quality prismatic machined components across a diverse spectrum of industries such as industrial power generation, aerospace and motorsport. Their experience and capability in CNC machining not only enables them to provide superior value, but in consultation with their clients , they can help diversify customer business by sharing knowledge and skills, ultimately allowing customers to focus resources on their own key objectives. www.mgsprecision.co.uk
www.lidsters.com E-mail: info@namtec.co.uk
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Event Reviews and Upcoming Events
Event Reviews Where’s your competitive edge for 2014? The Workstation, Sheffield 18th December
currently undertaking their second project with this funding scheme. There was also more than ample time provided for companies and solution providers to network amongst one another and discuss potential project ideas on new product/process development as well as improvements in products and processes (just to name a few). The event proved very productive and a number of companies are now engaged in creating project proposals and two projects have been funded as a direct result.
The aim of this event was to provide Yorkshire & Humber companies with the opportunity to improve their competitiveness and sustainability via the ERDF funded Direct Company Support (DCS) scheme, administered by NAMTEC. This breakfast meeting presented itself with a great turnout from companies around the region. Commencing with an overview of the scheme from the Director of NAMTEC, Alan McLelland, delegates then heard from the Managing Director of Disposables UK who presented their case study of the support and experience they received via the DCS scheme. David spoke about how the project increased the competitive position of Disposables UK Ltd, defending their current market share and providing them with the opportunity to relocate into larger premises. Disposables UK are
For companies interested in the Direct Company Support scheme, please contact Betime Nuhiji (e: betime.nuhiji@ namtec.co.uk) to discuss further.
Castings: The Foundry of the Future AMRC Diamond Jubilee Knowledge Transfer Centre (KTC), Rotherham 19th February Too often casting is thought of as an old fashioned metal manufacturing process. However, this notion is changing, as evidenced at the recent casting event held at the AMRC. With over 100 delegates gathering together from across the globe, the meeting was an opportunity for
the casting community to engage with one another around the developments being made in casting processes. Professor Keith Ridgway, Executive Dean of the University of Sheffield AMRC, commenced the proceedings by outlining the vision to expand the casting knowledge and technology base within the AMRC through developments within our internationally recognised centre, Castings Technology International (Cti). With a significant investment in casting research, the AMRC envisages a UK R&D centre of excellence for large scale and high performance castings. Peter Smith (Weir Group) and Richard Gould (Cti) opened the technical sessions, discussing the drivers for developing casting processes and how performance advancements have been made on impellers and diffusers. Factors included reductions in manufacturing costs, CO2 emissions and power consumption, whilst retaining mechanical integrity, geometries, contamination free surfaces as well as being compliant with industry standards and delivering on time and cost. ESI UK Ltd. followed this to inform industries of the importance of applying
simulation techniques to enhance the manufacturing process and in turn the quality of components. Methods included the prediction of microstructure and solidification of the molten metal. After a session break out, the afternoon introduced topic areas including the value of implementing training into the casting community, and how industries can work with the Health and Safety Executive (HSE) to improve their H&S procedures. In conclusion of the event, delegates had an opportunity to take a tour around the casting facility at Cti, and observe the various technologies available to industries. The importance of developing knowledge and technology within casting designs and processes was drawn upon throughout the day. Stephen Nagle, Production Director at Draycast Foundries Limited stated “The event has been very informative. There are a lot of obviously different industries and people attending today, so the variety of subject matters works well. I found the event to be of great benefit with the interesting technical presentations and enjoyed the day in general.”
Upcoming Events Manufacturing 2050
Factory 2050
AMRC, Rotherham 10th April 2014
Latest Advances in Arc Welding for Industry
Are you a Yorkshire & Humber SME with an interest in robotics, automation or large volume metrology?
Cedar Court Hotel, Wakefield 14th May 2014
The AMRC’s Integrated Manufacturing Group (IMG) invites you to attend their open day – a showcase of the projects and equipment they have been developing.
The Forum is delighted to have assembled an excellent series of presenters who will give an insight into the wide range of improvements in both technology and scientific understanding that have come about in recent years.
Come along and see how you can get involved in the research projects that IMG are working on. There may also be an opportunity for your company to have a FREE 2 day project carried out by a member of the IMG team to help you become more competitive or sustainable. To book your free place email Chloe Lidster on chloe.lidster@namtec.co.uk or call 0114 222 6661 for more details.
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In addition, the event will touch upon some of the future challenges facing the area of thinking not only of technology, but also in terms of availability of skills, qualifications and future demand. Presenters confirmed so far include Rolls-Royce, TWI, Nuclear AMRC & ITW Welding Products. Book online at www.namtec.co.uk/events