This Industrial Doctoral Centre (IDC) addresses a national need by building on the strengths of the existing EngD in Micro- and NanoMaterials and Technologies (MiNMaT) and the University of Surrey's excellent track record of working with industry to provide a challenging, innovative and transformative research environment in materials science and engineering. Following the proven existing pattern, each research engineer (RE) will undertake their research with their sponsor at their sponsor's premises. The commitment of potential sponsors is demonstrated in the significant number of accompanying letters of support. Taking place over all four years, carefully integrated intensive short courses (normally one week duration) form the taught component of the EngD. These courses build on each other and augment the research. By using a core set of courses, graduates from a number of physical science/engineering disciplines can acquire the necessary background in materials. This is essential as there are insufficient numbers of students who have studied materials at undergraduate level. The research focus of this IDC will be the solution of academically challenging and industrially relevant processing-microstructure-property relationship problems, which are the corner-stones of the discipline. This will be possible because REs will interact with internationally leading academics and have access to a suite of state-of-the-art characterisation instrumentation, enabling them to obtain extensive hands on experience. As materials features as one of the University's seven research priority areas, there is strong institutional support as demonstrated in the Vice Chancellor's supporting letter, which pledges 2.07M of new money for this IDC. As quality and excellence run through all aspects of this IDC, those graduating with an EngD in MiNMaT will be the leaders and innovators of tomorrow with the confidence, knowledge and research expertise to tackle the most challenging problems to keep UK industry ahead of its competitors.

Fibre-reinforced composites are finding increased usage in load-bearing structures in a variety of applications in marine, automotive and rail transport industries owing to their specific strength and stiffness properties. A serious problem with these composite materials, particularly glass-reinforced polymeric composites, which are the most prevalent in marine and other surface transport applications, is that they support combustion and in fire conditions burn, most often with heavy soot and smoke. Insulation can reduce the fire hazard, but does not eliminate it. Moreover the insulation adds weight and cost to apply.The combustible part of the composite is organic resin matrix. Most common method of fire retarding the resin and hence, the overall composite is the physical and chemical modification of the resin by either adding fire retardant element in the polymer backbone or using fire retardant additives in the resin. For polyester or vinyl ester resins, usually halogenated chemicals are used. While the presence of halogen significantly reduces the flammability of the resin, due to increasing environmental awareness and strict environmental legislations thereof, halogen - containing fire retardants are being strictly scrutinised. When non-halogen flame retardants are used, invariably they are required in large quantities (>30% w/w) to achieve required level of fire retardancy. The high concentrations of additives however, can reduce the mechanical properties of the composite. Moreover, they also affect resin's processability for resin transfer moulding technique, commonly used for these types of composites. We propose here a step change in the resin matrix by reducing the combustibility of vinyl ester and/or polyester resin by co-blending with inherently fire retardant resins, such as phenolic or melamine-formaldehyde resin.This proposal is a joint attempt by 'Fire Materials' group at the University of Bolton and 'Fluid Structure Interactions Research Group (FSIRG) at the University of Southampton to develop, construct, test and model novel, fire-retardant composites, initially for marine applications. The principal focus is to develop a modified polymeric matrix to reduce the combustibility of the vinyl ester or polyester resins by blending with appropriately modified phenolic and melamine resins, which will increase the thermal stability and char-forming capacity of the matrix. The physical and chemical properties of the modified resin will be optimised to enable: (a) the resin to be infusible for moulding leading to good processing ability: (b) low temperature cure capability to maximize compatibility and bonding with glass fibres; and (c) up-scaling to produce large laminates and structures. It is proposed that two different approaches will be taken: the first one 'Material' based, mainly by Bolton, and the other 'Structure' based, to which both Bolton and Southampton will contribute. The specific tasks include resin blending, chemical / physical modification of the resin, process modelling and resin infusion, composite laminate preparation and flammability evaluation. The composite laminates and structures thus produced are expected to comply with the fire performance requirements contained in the International Convention for the Safety of Life at Sea (SOLAS) as `IMO/HSC Code (Code of Safety for High Speed craft of the International Maritime Organisation). Additionally, the structural performance of the composite would be expected to be comparable with current glass/vinyl ester. We also propose to conduct fire performance modelling, mechanical characterisation and progressive damage analysis from a structural design viewpoint.We expect these composites to find applications also in other engineering arenas for which low-weight, thermally resistant and fire-retardant structures are increasingly being sought.

Advanced composite materials consist of reinforcement fibres, usually carbon or glass, embedded within a matrix, usually a polymer, providing a structural material. They are very attractive to a number of user sectors, in particular transportation due to their combination of low weight and excellent material properties which can be tailored to specific applications. Components are typically manufactured either by depositing fibres into a mould and then infusing with resin (liquid moulding) or by forming and consolidation of pre-impregnated fibres (prepreg processing). The current UK composites sector has a value of £1.5 billion and is projected to grow to over £4 billion by 2020, and to between £6 billion and £12 billion by 2030. This range depends on the ability of the industry to deliver structures at required volumes and quality levels demanded by its target applications. Much of this potential growth is associated with next generation single-aisle aircraft, light-weighting of vehicles to reduce fuel consumption, and large, lightweight and durable structures for renewable energy and civil infrastructure. The benefits of lightweight composites are clear, and growth in their use would have a significant impact on both the UK's climate change and infrastructure targets, in addition to a direct impact on the economy through jobs and exports. However the challenges that must be overcome to achieve this growth are significant. For example, BMW currently manufacture around 20,000 i3 vehicles per year with significant composites content. To replace mass produced vehicles this production volume would need to increase by up to 100-times. Airbus and Boeing each produce around 10 aircraft per month (A350 and 787 respectively) with high proportions of composite materials. The next generation single aisle aircraft are likely to require volumes of 60 per month. Production costs are high relative to those associated with other materials, and will need to reduce by an order of magnitude to enable such growth levels. The Future Composites Manufacturing Hub will enable a step change in manufacturing with advanced polymer composite materials. The Hub will be led by the University of Nottingham and University of Bristol; with initial research Spokes at Cranfield, Imperial College, Manchester and Southampton; Innovation Spokes at the National Composites Centre (NCC), Advanced Manufacturing Research Centre (AMRC), Manufacturing Technology Centre (MTC) and Warwick Manufacturing Group (WMG); and backed by 18 leading companies from the composites sector. Between the Hub, Spokes and industrial partners we will offer a minimum of £12.7 million in additional support to deliver our objectives. Building on the success of the EPSRC Centre for Innovative Manufacturing in Composites (CIMComp), the Hub will drive the development of automated manufacturing technologies that deliver components and structures for demanding applications, particularly in the aerospace, transportation, construction and energy sectors. Over a seven year period, the Hub will underpin the growth potential of the sector, by developing the underlying processing science and technology to enable Moore's law for composites: a doubling in production capability every two years. To achieve our vision we will address a number of research priorities, identified in collaboration with industry partners and the broader community, including: high rate deposition and rapid processing technologies; design for manufacture via validated simulation; manufacturing for multifunctional composites and integrated structures; inspection and in-process evaluation; recycling and re-use. Matching these priorities with UK capability, we have identified the following Grand Challenges, around which we will conduct a series of Feasibility Studies and Core Projects: -Enhance process robustness via understanding of process science -Develop high rate processing technologies for high quality structures

The theme area is manufacturing of engineering composites structures, specifically those which comprise continuous high performance fibres held together with a polymeric matrix. The relevant industry areas include aerospace, automotive, marine, wind energy and construction. The proposal demonstrates continuing and growing need in the UK polymer composites manufacturing sector for suitably technically qualified individuals, able to make positive and rapid impact on its international manufacturing competitiveness. Extension of a newly created Industrial Doctorate Centre in Composites Manufacture fills an existing gap in provision of industrially focussed higher level education in the UK, in the specialist discipline of polymer composites manufacturing. It has its centre of gravity in Bristol, with the rapidly expanding National Composites Centre (NCC) the natural home-base for the cohorts of composites manufacturing Research Engineers embedded in the composites manufacturing industry. This new hub of applied research activity focussed at TRL 3-5 is different from but highly complementary to the outputs of composites manufacturing PhD students within the EPSRC Centre for Innovative Manufacturing in Composites (CIMComp), working on more fundamental research topics in composites manufacture at TRL 1-3. Achieving a clearer definition of the industrial composites manufacturing challenges and of new knowledge base requirements will provide direction for the industrially relevant accompanying fundamental research. The EPSRC Centre for Innovative Manufacturing in Composites has established and maintains close management overview of this IDC , as well as fostering links with related CDTs within the wider High Value Manufacturing Catapult, initially specifically the AMRC Composites Centre IDC in Machining Science. Over time such connections will establish a critical mass of industrially focussed manufacturing research activity in the UK, raising the national and international status of the EngD brand in the composites industry, in academia and in professional institutions by targeted dissemination through CIMComp in conjunction with the NCC

The Cranfield IMRC vision is to grow the existing world class research activity through the development and interaction between:Manufacturing Technologies and Product/Service Systems that move UK manufacturing up the value chain to provide high added value manufacturing business opportunities.This research vision builds on the existing strengths and expertise at Cranfield and is complementary to the activities at other IMRCs. It represents a unique combination of manufacturing research skills and resource that will address key aspects of the UK's future manufacturing needs. The research is multi-disciplinary and cross-sectoral and is designed to promote knowledge transfer between sectors. To realise this vision the Cranfield IMRC has two interdependent strategic aims which will be pursued simultaneously:1.To produce world/beating process and product technologies in the areas of precision engineering and materials processing.2.To enable the creation and exploitation of these technologies within the context of service/based competitive strategies.