Henry Royce Institute
About us
The Henry Royce Institute is the UK’s national institute for advanced materials research and innovation.
Royce at the University of Sheffield is leading the Advanced Metals Processing research area of the Henry Royce Institute. We are equipped with state-of-the-art facilities to help accelerate university and industry ideas through to an industry production scale in order to meet our global challenges.
Over two purpose-built sites, our dynamic team of engineers support a vertically-integrated factory that can produce new alloys through to near net shape products through both solid and liquid processing. We are already assisting the development of new UK supply chains in sectors ranging from space components to electric car parts from recycled aerospace waste
Products & services
Compositional Characterisation
Our team can help determine compositional variance in your materials. Bulk elemental and crystallographic composition determination provides insight into manufacturing processes whilst compositional mapping techniques help understand homogeneity in final products. Compositional characterisation is the study of the elemental and chemical makeup of a material, determining what it is made of and in what proportions, which is fundamental to materials science. This capability is a core element of the Imaging and Characterisation theme at the Henry Royce Institute and the University of Sheffield. Royce at the University of Sheffield's facilities utilise powerful techniques like Inductively Coupled Plasma Mass Spectrometry (ICP-MS) to precisely measure trace and bulk elemental composition in various materials. Furthermore, Electron Microscopy techniques, specifically when equipped with Energy Dispersive X-ray Spectroscopy (EDS) or Wavelength Dispersive X-ray Spectroscopy (WDS), provide spatially-resolved compositional mapping. Understanding a material's composition is crucial for optimising performance in Royce's key areas, such as Advanced Metals Processing and the development of new alloys. Therefore, compositional characterisation is essential for both materials discovery and quality control across academic and industrial projects hosted at the Royce Translational and Discovery Centres. Capabilities: Scanning Electron Microscopy (inc Electron Backscatter Diffraction)
Alloy Development
Using a suite of state-of-the-art equipment our expert team can assist in the development of novel alloys for industrial application as port of our vertically integrated factory within the Advanced Metals Processing theme. Our unique capabilities, split across the Royce Discovery and Translational Centres, enable the end-to-end creation of new alloys, from concept to industry-ready scale-up. The Materials Discovery and Prototyping platform provides critical melting equipment, like Vacuum Induction Melting and Arc Melting, to precisely control the composition of novel metallic systems. This initial production is seamlessly linked to Thermomechanical Processing, which uses machines like the Hot Rolling Mill to shape and refine the alloy microstructure, simulating industrial manufacture. By bridging the gap between small-scale lab research and industrial application, Royce Sheffield is accelerating the deployment of next-generation alloys crucial for sectors like aerospace, nuclear, and automotive. The focus on resource-efficient and high-performance alloys supports global challenges in the transition to net-zero and a circular economy. Capabilities: Arc Melting Vacuum Induction Melting (<10kg and <25kg) Thin Film Deposition Case Study: An Experimental Approach to Simulate Ejecta on Titanium Spacecraft Surfaces Under Re-Entry Extreme Environment Conditions - https://sheffield.ac.uk/royce-institute/impact-and-outreach/impact/simulating-ejecta-titanium-spacecraft-surfaces
Powder Production
We're able to develop novel, bespoke alloys in small powder batches with our state-of-the-art powder production equipments. This can be trialled and evaluated through various NNS technologies in order to achieve the optimum feedstock for each process. With a range of equipment across our two sites we're able to develop and produce small batches of novel, bespoke alloy powder. These can be tailored to an optimum feedstock need for a variety of onwards needs such as additive manufacturing. Our capabilities enable us to produce powder through atomisation or milling, with the resulting powders being refined through the spheroidisation process. The Arcast atomiser utilises induction melting and inert gas atomisation to produce high-quality, technically-advanced powders from a variety of metals such as titanium, iron, copper, nickel. and cobalt-based alloys. The Union Process mills are fast, efficient and reliable for the fine grinding of media including carbon steel, stainless steel, chrome, and tungsten carbide. They are ideal for formulating, quality control, and scale-up studies, with results being repeatable for maximum credibility. The Tekna spheroidiser uses high energy plasma to create highly spherical and dense metal powders providing consistent results and better flowability. The process also removes contamination and reduces oxygen meaning it is a vital step for recycling powder. Capabilities: Atomisation Attrition Milling Spheroidisation
Powder Consolidation
Our capabilities support the key technical challenge of innovating processes to efficiently fabricate and test material libraries, whilst simultaneously capturing sufficient information which can be shared with manufacturers to enable rapid deployment to occur. Additive Manufacturing technologies developed through Royce at the University of Sheffield hold the potential to displace existing technologies with reduced material waste and increased part complexity. Melt Spinner casts a thin ribbon of rapidly quenched amorphous material in 100g batches, and is suitable for Al, Fe, Ni, and Cu alloys. In powder metallurgy, HIP allows us to compress a volume of metal powder at such high temperatures and pressures, that through a combination of deformation, creep, and diffusion, you actually create a product with an homogenous annealed microstructure (compact solid) with minimal or no impurities in the materials. Meanwhile our research CIP is used to shape form powders into a green body, prior to sintering. This model allows the pressing of various shapes, including discs, bars, and tubes, and is therefore a near-net-shape process. Field Assisted Sintering Technology/Spark Plasma Sintering (FAST/SPS) uses a DC electric current to directly heat the mould and/or sample through Joule heating. This direct heating allows high heating rates and low processing cycle times to be achieved. Lower temperatures and mould pressures are also typical compared to conventional hot pressing and sintering techniques. FAST/SPS offers new possibilities to manufacture numerous materials with potentially extraordinary characteristics. Capabilities: Additive Manufacturing (Laser Powder Bed Fusion, Directed Energy Deposition, Binder System) Isostatic Pressing (Hot and Cold) Field Assisted Sintering Technology/Spark Plasma Sintering Conform Extrusion
Metals Processing
Our Additive Manufacturing technologies hold the potential to displace existing technologies with reduced material waste and increased part complexity. Melt Spinning casts a thin ribbon of rapidly quenched amorphous material in 100g batches, suitable for Al, Fe, Ni, and Cu alloys. HIP compresses a volume of metal powder at high temperature and pressure, causing deformation, creep, and diffusion to create a homogenous annealed microstructure (compact solid) with minimal or no impurities. Meanwhile our research CIP is used to form powders into a green body, prior to sintering, through the pressing of various shapes, including discs, bars, and tubes. Field Assisted Sintering Technology/Spark Plasma Sintering (FAST/SPS) uses electrical currents to heat a mould and/or sample. This method allows high heating rates and low processing cycle times. FAST/SPS offers new possibilities to manufacture numerous materials with potentially extraordinary characteristics. The Fenn Hot Rolling Mill has been designed specifically for the University of Sheffield to roll steels, titanium alloys, and nickel-based alloys from a maximum starting thickness of 80mm to a finished thickness of 3mm. The Conform extruder can take former wastes, such as powder from near-net-shape production or swarf from machined components, and produce useful wire. These processes offer new, unique pathways in the processing of novel alloys, or valorisation of waste streams for new recycling and sustainability models in metal manufacturing.
Non-Metals Processing
Additive Manufacturing technologies developed through Royce at the University of Sheffield hold the potential to displace existing technologies with reduced material waste and increased part complexity. HIP allows us to compress a volume of metal powder at such high temperatures and pressures, that through a combination of deformation, creep, and diffusion, you actually create a product with an homogenous annealed microstructure (compact solid) with minimal or no impurities in the materials. Meanwhile our research CIP is used to shape form powders into a green body, prior to sintering. This model allows the pressing of various shapes, including discs, bars, and tubes, and is therefore a near-net-shape process. Field Assisted Sintering Technology/Spark Plasma Sintering (FAST/SPS) uses a DC electric current to directly heat the mould and/or sample through Joule heating. This direct heating allows high heating rates and low processing cycle times to be achieved. Lower temperatures and mould pressures are also typical compared to conventional hot pressing and sintering techniques. FAST/SPS offers new possibilities to manufacture numerous materials with potentially extraordinary characteristic
Biological Characterisation
Our biological characterisation experts work at the molecular and cellular level, with single molecule and atomic force microscopes unravelling the complexities of DNA interactions within cells. Biological Characterisation involves using advanced techniques to probe the structure, properties, and behaviour of biological materials. At Royce at the University of Sheffield this capability is a key component of the overarching Imaging and Characterisation research theme. Much of the equipment associated with this area are situated within the Nanocharacterisation Lab at the Royce Discovery Centre, which features specialised equipment such as high-resolution Atomic Force Microscopes (AFM) capable of imaging fragile biological samples. This nano-scale imaging is essential for understanding fundamental biological processes, such as the structure and interactions of DNA and biomolecules. Such sophisticated biological characterisation directly contributes to the Henry Royce Institute's research into Biomedical Materials, supporting the development of next-generation medical devices and therapeutics. Capabilities: Atomic Force Microscopy Optical Tweezers Inductively Coupled Plasma Mass Spectrometry Nanoindentation Optical Profilometry
Modelling and Simulation
We support researchers who use modelling and simulations themselves, but also provide a route for new collaborations between industry and academia or between simulation and experiment. Our goals are to: Accelerate innovation in materials through physics-based modelling and computational simulation. Enable data-centric and AI-based materials research. Facilitate collaboration to exploit complementarity in simulation and experiment and bring together academia and industry. The Modelling and Simulation Research Area is integral to all Royce activities and serves as a key pillar of the Institute’s Materials 4.0 strategy, which drives the acceleration of materials innovation through digital methods. This includes support for the new Royce Centre for Doctoral Training in Developing National Capability for Materials 4.0.
Materials and Thermal Treatment for Radioactive Waste Management
As a leading hub for advanced materials science and engineering, Royce at the University of Sheffield provides an unparalleled platform for businesses dedicated to advancing nuclear technologies. Our world-class facilities, including cutting-edge laboratories and simulation capabilities, provide researchers and entrepreneurs with the tools they need to improve the efficiency, safety, and viability of both fission and fusion reactors. Through collaborative partnerships with academic leaders, industry innovators and governmental agencies, we have convened a community focused on accelerating the development and deployment of next-generation nuclear technologies. Whether you're pioneering new reactor designs, optimising materials for extreme environments, or exploring fusion as a clean energy source, Royce at the University of Sheffield is your partner of choice in the drive for a sustainable and prosperous energy landscape.
News
Collaboration with MatNex helps reduce reliance on REE
Alloy manufacture and imaging and characterisation proves the effectiveness of MatNex's AI material property predictions allows rapid novel alloy development for magnetic materials
Using 3D Printing to help us see into space
Nanosatellites offer a way to greatly increase access to space-based imaging. Whether these telescopes are looking to space for astronomical measurements, or to earth to track climate and weather, the costs are fraction of the large-scale satellites.
'FAST-Forge' process developed at Royce at the University of Sheffield could revolutionise production of titanium goods
The City of Steel has brought forward a new metal revolution; Researchers at the University of Sheffield are paving the way for more sustainable titanium production