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Steel is the backbone of modern society, serving as the foundation for many industries globally. The widespread growth of the steel industry is tied directly to the Industrial Revolution and since then this growth has not stopped; global crude steel production was 1.7 billion tonnes in 2017. Over the years both steel materials and the processes we use to make them have been researched and developed continuously, but a lack of government support for industry meant new investment in existing steel manufacturing infrastructure was limited. In recent decades huge amounts of steel, sold cheaper than we can make it in the UK, have flooded the market. This comes primarily from Europe and Asia. In order to compete in this key industry the UK has to shift its focus from large volumes of commodity material to smaller volumes of high value-added material, and to achieve this in both an environmentally and economically sustainable way. This has been accepted in the industry but low profit margins have meant there are no funds available to invest in large capital projects and enable transformation on the required scale with current technologies. This ambitious project, AM-Steel, aims to start to address this challenge by providing the UK steel industry with the knowledge, technology and competitive advantage required to kick-start a transformation towards digital technologies - specifically additive manufacturing (AM). The AM process is currently used in high-tech and high-value industries including Aerospace and Medical, where the design freedom and high material utilisation makes the economic benefit easily seen, and is experiencing unprecedented revenue growth of 40% year-on-year for the past 5 years. With the maturing of this technology, AM has started to spread into a broader range industry sectors, where steel is the dominant material. It is projected that from 2020 steel will have the largest market share in the metal AM sector, overtaking Titanium, Nickel, and Aluminium alloys. AM requires high quality metal alloy powders. There are less than ten steel alloys widely available as powders for AM, mostly stainless and tool steels, compared to the thousands of alloys available to traditional productions routes (such as casting or forging and subtractive machining). This project will use the wealth of metallurgical knowledge in the steel industry, advanced thermodynamic modelling, and world-leading characterisation facilities - all available in the UK - to create a range of bespoke steel alloy compositions tailored to realise the enhanced processability at lower cost for general engineering applications, by utilising the unique benefits of the AM process. AM-Steel will establish AM technology capability in the UK steel industry; enabling the industry to produce high value-added powder materials for AM, improving the productivity of the industry's heritage assets using these technologies, and transforming the industry and its supply chain through digital manufacturing. AM-Steel is strategically aligned with the Liberty GREENSTEEL policy: to serve local markets using local materials; produced using green, renewable long-term sources of power; re-invigorating the subsequent engineering supply chain and delivering innovative solutions that provide a competitive advantage to customers. AM-Steel will contribute greatly to Liberty's target to be carbon neutral by 2030.
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