Dr Emma Calvert
Position
Development Engineer
Funding body
Sheffield Forgemasters
Dr. Emma Calvert completed her Materials Science and Engineering undergraduate degree at The University of Sheffield. During her degree, she had work placements at Sheffield Forgemasters International Limited, TIMET UK Limited, and Alcoa Forging and Extrusions (formerly Firth Rixson Forgings Limited).
Past Research Focus
Dr. Emma Calver worked on the FAST-forging of Ti-5553. Her PhD was sponsored by SAFRAN Landing Systems (formerly Messier-Bugatti-Dowty), who make landing gear systems for commercial aircraft. Although making landing gear from titanium alloys is highly beneficial, as they have higher strength-to-weight ratio and reduced corrosion maintenance when compared to stainless steels, the high cost of titanium alloy production means it is uneconomical to replace stainless steel parts with titanium ones.
A cheaper titanium processing route is therefore being investigated, in order to determine if titanium alloy parts can viably replace stainless steel parts. This processing route involves: producing titanium alloy powder directly from titanium ore via the Metalysis (FFC) electrolysis process; consolidating the powder to pre-forged billet via the FAST (field-assisted sintering technology) process; forging the billet in one or two steps; heat treating to produce optimal microstructure; and machining to final shape, as with conventional processing.
The main aim of her project was to tailor the final microstructure of Ti-5553 during the FAST process, forging process, and subsequent heat treatment. This demonstrated the suitability of the FAST-forge process for a conventional beta titanium alloy, and allowed a direct comparison with material produced by the conventional processing route.