As the second most widely used structural metal in the world, after steel, Al-alloys have a low density (3 times lighter than steel), high corrosion resistance and a good combination of physical and mechanical properties. In terms of specific strength (strength/density), Al-alloys outperform conventional steels and match the performance of advanced high strength steels (AHSS) developed in recent years. This makes Al alloys particularly attractive for applications in the transport industry. The demand for aluminium products has increased 30-fold since 1950 and this exceptional growth is predicted to continue well into the first half of the 21st century. However, there is both good and bad news about aluminium. The bad news is that aluminium production uses 3.5% of global electricity and causes 1% of global CO2 emissions resulting in a large negative impact on our environment; and the good news is that aluminium is in principle infinitely recyclable and its recycling requires only 5% of the energy required for primary metal production. In addition, since 1908 we have cumulatively produced over 1 billion tonnes of aluminium, and more than 75% of this aluminium still exists as accessible stock in our society. Such metal stock will become our energy "bank" and a rich resource for meeting our future needs. Our long term vision is "full aluminium circulation", in which the global demand for aluminium is met by a full circulation of secondary aluminium (with only limited addition of primary aluminium each year) through reduced usage, reuse, remanufacture, closed-loop recycling and effective recovery and refining of secondary aluminium. Under this shared vision, BCAST (a global leader in light metal research) and Constellium (a global leader in aluminium lightweight structure supply) have established a strategic research partnership for developing high performance Al-alloys and their applications in lightweight vehicle constructions, with research projects covering a wide range of technology readiness levels. Under the shared vision for full metal circulation, BCAST and Constellium have identified the shared research challenges and co-created a coherent fundamental research programme on STEP (STrain Enhanced Precipitation) Al-alloys to complement the existing applied research activities. This programme aims to strengthen the existing, strategic research partnership between Constellium and BCAST through successful execution of a co-created STEP Al research programme, which will accelerate academic research impact on business, balance capability between fundamental and applied research, and will build and consolidate the UK's internationally leading position in aluminium research. In the STEP Al programme, we will develop a new generation of high performance Al-alloys with ultra-high strength (twice the strength of their conventional counterparts), good ductility, high crashworthiness and high thermal conductivity; we will develop a novel direct chill (DC) casting process and thermomechanical processing procedures to realise the full potential of STEP Al-alloys; we will deliver new insights into the precise precipitation mechanisms and the solute-dislocation-precipitate interactions to underpin both materials and processing technology development; and we will also develop a holistic approach to the design of lightweight automotive structures to demonstrate the full potential of our research outcomes. Successful execution of the STEP Al programme will deliver significant advances in nucleation science, physical metallurgy, advanced alloy development, materials processing technologies and holistic engineering design. These will in turn have profound impact on UK productivity, the overall UK economy and our environment.

Natural resources are the foundation of our life on Earth, without which neither our economy nor society can function. However, due to continued resource overconsumption and the rapidly increasing world population, the global demand for natural resources and the related intense pressure on our environment have reached an unprecedented and unsustainable level. A shocking fact is that our cumulative consumption of natural resources over the last 60 years is greater than that over the whole of previous human history. With an anticipated world population of 9.3bn in 2050, the predicted global natural resource consumption will be almost tripled. This level of overconsumption is obviously not sustainable, and there is a compelling need for us to use our advanced science and technology to work with, rather than to exploit, nature. Metallic materials are the backbone of manufacturing and the fuel for economic growth. However, metal extraction and refining is extremely energy intensive and causes a huge negative impact on our environment. The world currently produces 50MT of Al and 2bnT of steel each year, accounting for 7-8% of the world's total energy consumption and 8% of the total global CO2 emission. Clearly, we cannot continue this increasing and dissipative use of our limited natural resources. However, the good news is that metals are in principle infinitely recyclable and that their recycling requires only a small fraction of the energy required for primary metal production. Between 1908 and 2007 we produced 833MT of aluminium, 506MT of copper and 33bnT of steels. It is estimated that more than 50% of this metal still exists as accessible stock in our society. Such metal stock will become our energy "bank" and a rich resource for meeting our future needs. The UK metal casting industry adds £2.6bn/yr to the UK economy, employs 30,000 people, produces 1.14bnT of metal castings per year and underpins the competitive position of every sector of UK manufacturing. However, the industry faces severe challenges, including "hollowing-out" over the past 30 years, increasing energy and materials costs, tightening environmental regulations and a short supply of skilled people. We are now establishing the Future Liquid Metal Engineering Hub to address these challenges. The core Hub activities will be based at Brunel strongly supported by the complementary expertise of our academic spokes at Oxford, Leeds, Manchester and Imperial College and with over £40M investment from our industrial partners. The Hub's long-term vision is full metal circulation, in which the global demand for metallic materials is met by a full circulation of secondary metals (with only limited addition of primary metals each year) through reduced usage, reuse, remanufacture, closed-loop recycling and effective recovery and refining of secondary metals. This represents a paradigm shift for metallurgical science, manufacturing technology and the industrial landscape. The Hub aims to lay down a solid foundation for full metal circulation, demonstrated initially with light metals and then extended to other metals in the longer term. We have identified closed-loop recycling of metallic materials as the greatest challenge and opportunity facing global manufacturing industry, and from this we have co-created with our industrial partners the Hub's research programme. We will conduct fundamental research to deliver a nucleation centred solidification science to underpin closed-loop recycling; we will carry out applied research to develop recycling-friendly high performance metallic materials and sustainable metal processing technologies to enable closed-loop recycling; we will operate a comprehensive outreach programme to engage potential stakeholders to ensure the widest possible impact of our research; we will embed a centre for doctoral training in liquid metal engineering to train future leaders to deliver long-lasting benefits of closed-loop recycling.

This Centre for Doctoral Training in Embedded Intelligence, the first in the UK, addresses high priority areas for economic growth such as autonomous complex manufactured products and systems, functional materials with high performance systems, data-to-knowledge solutions (e.g. digital healthcare and digitally connected citizens), and engineering for industry, life and health, which are also key priorities for Horizon 2020, the new EU framework programme for research and innovation. Horizon 2020 explicitly spells out ICT and Manufacturing as key industrial technologies. Its remit fits the EPSRC priority areas of ICT for Manufacturing and Data to Knowledge, and has an impact on industrial sectors as diverse as logistics, metrology, food, automotive, oil & gas, chemistry, or robotics. In addition, our world (homes, transport, workplaces, supplies of food, utilities, leisure or healthcare) is constantly seeking for interactive technologies and enhanced functionalities, and we will rely on these graduates who can translate technologies for the end-user. The uniqueness of this Centre resides on the capability to innovatively address a myriad of Embedded Intelligence challenges posed by technical needs ranging from the EI supply chain: the design stage, through manufacturing of embedded or on-bedded devices, to the software behind data collection, as well as integrative technologies, to finally the requirements from end-users. The thematic areas, discussed conjointly with industry during the preparation of this proposal, allow us also to recruit students from a vast range of educational backgrounds. A strong user pull defines the nature of the challenges that this CDT will tackle. The graduates who shall come to alleviate the shortage of skilled engineers and technologists in the field will be exposed to the following thematic areas: > Device design, specification of sensors and measurement devices (power scavenging, processing, wire & wireless communications, design for low power, condition monitoring); > Packaging & integration technologies (reliability and robustness, physical and soft integration of devices, sub-components and wider system environment); > Intelligent software (low level, embedded, system level, database integration, ontology interrogation, service oriented architectures, services design); > Manufacturing solutions (design for manufacture of embedded systems, advanced and hybrid manufacturing processes for embedding, process consolidation technologies, biomimetics and cradle-to-cradle for sustainability production, etc.); > Applications engineering (design and implementation of embedded technologies for in-time, in-line products, processes and supply chains; product and process design for embedded intelligence); > System Services: (i) Service Foundations (e.g., dynamically reconfigurable architectures, data and process integration and semantic enhanced service discovery); (ii) Service Composition (e.g. composability analyses, dynamic and adaptive processes, quality of service compositions, business driven compositions); (iii) Service Management and Monitoring (e.g. self: -configuring, -adapting, -healing, -optimising and -protecting) and (iv) Service Design and Development (e.g. engineering of business services, versioning and adaptivity, governance across supply chains). Our flagship, the 'Transition Zone' training, will facilitate the transition into doctoral studies in the first year of studies, and, closer to the end of the programme, out to industry or self-employment. As employable high calibre individuals with a good understanding of enterprising, commercialisation of research, social responsibility, gender equality and diversity, innovation management, workplaces, leadership and management, our doctorates will grow prosperity bottom up, enjoying a wealthy network of academic and industrial contacts from their years at the CDT, as well as their peers at the Centre.

Additive Manufacturing (AM) often known by the term three-dimensional printing (3DP) has been acknowledged as a potential manufacturing revolution. AM has many advantages over conventional manufacturing techniques; AM techniques manufacture through the addition of material - rather than traditional machining or moulding methods. AM negates the need for tooling, enabling cost-effective low-volume production in high-wage economies and the design & production of geometries that cannot be made by other means. In addition, the removal of tooling and the potential to grow components and products layer-by-layer means that we can produce more from less in terms of more efficient use of raw materials and energy or by making multifunctional components and products. The proposed Centre for Doctoral Training (CDT) in Additive Manufacturing and 3D Printing has the vision of training the next generation of leaders, scientists and engineers in this diverse and multi-disciplinary field. As AM is so new current training programmes are not aligned with the potential for manufacturing and generally concentrate on the teaching of Rapid Prototyping principles, and whilst this can be useful background knowledge, the skills and requirements of using this concept for manufacturing are very different. This CDT will be training cohorts of students in all of the basic aspects of AM, from design and materials through to processes and the implementation of these systems for manufacturing high value goods and services. The CDT will also offer specialist training on aspects at the forefront of AM research, for example metallic, medical and multi-functional AM considerations. This means that the cohorts graduating from the CDT will have the background knowledge to proliferate throughout industry and the specialist knowledge to become leaders in their fields, broadening out the reach and appeal of AM as a manufacturing technology and embedding this disruptive technology in company thinking. In order to give the cohorts the best view of AM, these students will be taken on study tours in Europe and the USA, the two main research powerhouses of AM, to learn from their international colleagues and see businesses that use AM on a daily basis. One of the aims of the CDT in AM is to educate and attract students from complementary basic science, whether this be chemistry, physics or biology. This is because AM is a fast moving area. The benefits of having a CDT in AM and coupling with students who have a more fundamental science base are essential to ensure innovation & timeliness to maintain the UK's leading position. AM is a disruptive technology to a number of industrial sectors, yet the CDTs industrial supporters, who represent a breadth of industrial end-users, welcome this disruption as the potential business benefits are significant. Growing on this industry foresight, the CDT will work in key markets with our supporters to ensure that AM is positioned to provide a real and lasting contribution & impact to UK manufacturing and provide economic stability and growth. This contribution will provide societal benefits to UK citizens through the generation of wealth and employment from high value manufacturing activities in the UK.

Historically, the discovery, development and application of metals have set the pace for the evolution of human civilisation, driven the way that people live, and shaped our modern societies. Today, metals are the backbone of the global manufacturing industry and the fuel for economic growth. In the UK, the metals industry comprises 11,100 companies, employs 230,000 people, directly contributes £10.7bn to the UK GDP, and indirectly supports a further 750,000 employees and underpins some £200bn of UK GDP. As a foundation industry, it underpins the competitive position of every industrial sector, including aerospace, automotive, construction, electronics, defence and general engineering. However, extraction and processing of metals are very energy intensive and cause severe environmental damage: the extraction of seven major metals (Fe, Al, Cu, Pb, Mn, Ni and Zn) accounts for 15% of the global primary energy demand and 12% of the global GHG emission. In addition, metals can in theory be recycled infinitely without degradation, saving enormous amounts of energy and CO2 emission. For instance, compared with the extraction route, recycling of steel saves 85% of energy, 86% GHG emission, 40% water consumption and 76% water pollution. Moreover, metals are closely associated with resource scarcity and supply security, and this is particularly true for the UK, which relies almost 100% on the import of metals. The grand challenge facing the entire world is decoupling economic growth from environmental damage, in which metals have a critical role to play. Our vision is full metal circulation, in which the global demand for metallic materials will be met by the circulation of secondary metals through reduce, reuse, remanufacture (including repair and cascade), recycling and recovery. Full metal circulation represents a paradigm shift for metallurgical science, manufacturing technology and the industrial landscape, and more importantly will change completely the way we use natural resources. Full metal circulation means no more mining, no more metal extraction, and no more primary metals. We will make the best use of the metals that we already have. We propose to establish an Interdisciplinary Circular Economy Centre, CircularMetal, to accelerate the transition from the current largely take-make-waste linear economy to full metal circulation. Our ambition is to make the UK the first country to realise full metal circulation (at least for the high-volume metals) by 2050. This will form an integral part of the government's efforts to double resource productivity and realise Net Zero by 2050. We have assembled a truly interdisciplinary academic team with a wide range of academic expertise, and a strong industrial consortium involving the full metals supply chain with a high level of financial support. We will conduct macro-economic analysis of metal flow to identify circularity gaps in the metals industry and to develop pathways, policies and regulations to bridge them; we will develop circular product design principles, circular business models and circular supply chain strategies to facilitate the transition to full metal circulation; we will develop circular alloys and circular manufacturing technologies to enable the transition to full metal circulation; and we will engage actively with the wider academic and industrial communities, policy makers and the general public to deliver the widest possible impact of full metal circulation. The CircularMetal centre will provide the capability and pathways to eliminate the need for metal extraction, and the estimated accumulative economic contribution to the UK could be over £100bn in the next 10 years.