Engineering Research using the Diamond Synchrotron

Engineering

Research Area

Innovation and advanced design approaches by engineers can solve complex real world problems. Novel concepts are needed to push performance boundaries and greater scientific insight is often needed to fully realise the design. Increased insight can be achieved by improving the materials and processes used in the manufacturing route or measuring parameters such as stress and strain directly to validate computational models. Additionally, in the event of catastrophic failure of the engineering system, a forensic method is often needed to re-engineer the component or system.

Diamond provides specialist analytical techniques for the atomic to microscale characterisation of materials ranging from high performance components and devices through to diagnostic tools and drug delivery technologies.

Stress and Strain

Measure the stress and strain to evaluate the mechanical performance of an engineering component or system in real time;
Study the residual stress and strain in a component that arises due to manufacturing processes by non-destructively mapping the strain profile in 3D;
Investigate failed components to determine the underlying cause and establish routes to re-engineer the component for future requirements.

Material Characterisation

Characterise the microstructure of a new material and understand how it evolved during the product life cycle;
Explore processing conditions to improve the microstructure and engineering performance;
Chemically and crystallographically map the material phases and determine detrimental features.

Corrosion

Chemically map the corrosion region to look at chemical segregation and understand nucleation points;
Understand the structure and chemical composition of a corrosion product;
Perform in situ experiments to follow a corrosion reaction and determine the kinetics;
Apply imaging methods to give a 3D view of the corroded region and measure physical features.

X-ray Imaging

Apply non-destructive imaging techniques to view inside a full engineering assembly at high magnification;
Understand solidification of materials by performing high speed radiography and tomography;
Uncover hidden cracks and deformation in static conditions or during in situ loading.

Related Case Studies
Related News

Related Case Studies

Optimising the conditions for additive manufacturing

The Problem profilephoto

Additive manufacturing (AM), was originally used for creating prototypes, but is now being adopted to create fully functional products. This method of manufacturing allows us to create complex shapes, to exact measurements. It works by fusing together metallic, ceramic or other powders into detailed 3D shapes, layer by layer, using laser light. During traditional manufacturing routes, like casting or forging, microstructures are formed over seconds to minutes. During AM, the intense laser heating melts and solidifies the materials in milliseconds, forming very different microstructures.

Stresses in steel during manufacturing

The Problem profilephoto

The automotive industry typically uses steel sheets for the bodywork of cars which is cut to the size of the part (i.e. roof, door or bonnet) and then stamped into the precise shape required. Although steel is a commonly-used material, the exact behaviour of the metal’s crystalline structure during these forming processes has yet to be fully mapped. By understanding how the ‘steel crystals’ react when undergoing stamping, new alloys could be created that offer greater flexibility and strength which might allow more complex shapes to be formed.

Measuring stress in breathing apparatus cylinders

The Problem profilephoto

Luxfer Gas Cylinders have been manufacturing high-pressure self-contained breathing apparatus (SCBA) and life-support cylinders for fire-fighters and first-responders since the early 1970s. Cylinders are required to be increasingly lightweight, efficient and safe storage solutions. Advanced carbon fibre-wrapped aluminium construction methods and a fabrication process called autofrettage aim to reduce weight and increase maximum working pressures of cylinders. However, since cylinders can be exposed to demanding conditions, it is critical that their structural integrity be maintained.