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The School of Engineering at MMU has longstanding research into many aspects of railway engineering. This commenced in 1998 under the leadership of Professor Simon Iwnicki, who carried out research into the interaction between railway vehicles and the track. The understanding of the dynamics of the wheel rail contact that has resulted from this work has been developed into a number of tools and techniques that are being used on a daily basis by the rail industry both to design new railway systems and to predict the deterioration of railway wheels and rails. This allows railway engineers to predict and control roughness growth on rails and to optimise wheel profiles and maintenance intervals on wheel and track.
This work is now helping the railway industry internationally to realise both economic and environmental impacts as track maintenance costs are reduced, safety levels are enhanced and passengers continue to switch from road to rail in increasing numbers. This is evidenced by the award of new research contracts and industry funding and by direct input into industry standards.
This case study deals with research undertaken at Plymouth University leading to the development of an innovative friction stir welding process (friction hydro-taper pillar processing, FHPP) and a bespoke welding platform that improves the assessment and repair methodology for creep damaged thermal power station components. This technology, developed in collaboration with Nelson Mandela Metropolitan University and with industry investment, enables power station engineers to extend the life of power generating plant leading to multi-million pound cost savings (over £66M in direct financial savings are demonstrated in this case) plus significant safety and societal impacts. It has been patented in South Africa and a spin-off company has been formed.
Please note that economic impact values were achieved in Rand (R) but are expressed in £ and therefore worth less in £ today than during the period when the stated impact was achieved.
The automotive and aerospace industries are keen to reduce their environmental impact and so have looked to move to lightweight materials. This creates issues in terms of joining, using and disposing of dissimilar materials. Oxford Brookes has therefore worked with national and multi-national companies in the adhesive, materials, automotive and aerospace industries to try to solve these problems. This has resulted in high quality research publications, innovative test equipment, improved numerical methods, novel designs, design guidelines, manufacturing procedures, British Standards, patents, commercial products and further funding. The impact of the work has global safety, environmental and economic benefits with multi-national aerospace and automotive companies implementing the results in current developments.
Research at the University of Manchester has supported the development of inertia and linear friction welding of high temperature materials for aeroengine application. The research has guided process parameter development and led to deployment of these new welding techniques at Rolls-Royce plc. In particular, inertia friction welding is now used in modern gas turbine engines, such as the Trent 900, which powers the A380, Trent 1000 for the Boeing 787 and Trent XWB for the Airbus A350. In addition, research has enabled blisk technology (welding of blades on disks), which has delivered up to 30% weight saving on critical rotating components.
Following the North Sea Piper Alpha oil rig accident in 1988 and subsequent Cullen inquiry, new and safer maintenance procedures were introduced. One of the most significant changes was the restriction in the use of welding repairs (hot work) in the maintenance of plant and pipework due to the risk of fire and explosion. Research at Newcastle provided a novel engineering model that formed the basis for implementation of a new repair technology. This used fibre reinforced polymer wraps to restore the integrity of pipes without `hot work' or any interruption of production, thus minimising operational costs and increasing worker safety. This new technology has now become industry standard with new ISO and ASME standards for pipeline repair established as mandatory standards in 2006 and 2008 respectively (ISO/TS 24817 — Composite repairs for pipework; and ASME PCC-2, Repair of pressure vessels and piping). The period 2008-2013 has seen considerable expansion, worldwide, of an industry offering materials and support services to enable composite repairs to be designed and carried out.
The UK Rail Industry has set itself a target of increasing capacity by a factor of two within 30 years for both passengers and freight. A central problem is to increase the capacity and performance of the (existing) rail network. Signalling systems and their safety is a major consideration. It is towards this long-term goal that we direct our research activity on signalling. Our research impacts both current practices and strategic planning within the Railway Industry:
The transport of people, goods, and utilities (e.g. electricity, oil, gas and water) is essential to civilised life, and in turn depends on a robust, reliable and affordable infrastructure. Since 1995, the University of Southampton Geomechanics Group (SGG) has led the development of an enhanced, science-based framework for understanding the behaviour of geotechnical transport infrastructure through monitoring, modelling and analysis. The techniques we have developed have been used by the builders, owners and operators of transport infrastructure both nationally and internationally to develop improved understandings of infrastructure geotechnical behaviour both during construction and in service. This has led to substantial savings in build, maintenance and operational costs; the implementation of effective remediation and management strategies; and significantly improved infrastructure performance.
The EKG technology developed by Newcastle has launched an entirely new spectrum of applications for geosynthetic materials and has resulted in changing established practice in civil, construction and mining engineering. The commercialisation of the technology, linking industry to applications of EKG products and processes, has been driven by the spin-out company Electrokinetic Limited. Amey, a leading international infrastructure services provider, incorporated the EKG technology into £1M projects for Network Rail and the Highways Agency in 2011-12. The end results were a 30% cost saving and 40% reduction in CO2 compared to established methods. The new range of EKG products has been recognised by British Standards, leading to the revision of BS 8006 for reinforced soil in 2010.
Research at Newcastle University on formal methods for the design of computing systems has had a major impact on the delivery of new high-dependability products by industry. The methods (VDM and Event-B), to which we have made significant contributions, have been embodied in tools (VDMTools, Overture, Rodin) and applied in industry. The reach of the work extends to industries in Europe (e.g. in the rail sector by Siemens, 2011) and Japan (e.g. in firmware design by Sony, 2008). Significance is seen in reported improvements in defect detection rates of up to a factor of 5 over previous processes and the cost-effectiveness of design processes. The "Mobile FeliCa" chip developed using VDMTools is now incorporated into over 200 million mobile phones worldwide. Our approach to disseminating research has engendered lively international and online end-user communities further developing and using the tools today.
Automated dry hyperbaric (high pressure) gas metal-arc welding (GMAW) is used in deep-sea pipelines for remote repair and "hot-tap" connections to operating pipelines. Cranfield's process can be used for depths of up to 2,500 metres. The process has been applied in production with a new joint being made at a depth of 265 metres on a live gas pipeline. As part of the Åsgard Subsea Compression project, it will improve the recovery from the Mikkel and Midgard reservoirs by around 280 million barrels of oil equivalents, worth more than 28 billion dollars at today's prices.