Professor Allan Hutchinson
Professor Emeritus
School of Engineering, Computing and Mathematics

Research
Centres and institutes
Groups
Publications
Journal articles
-
Raugei M, Kamran M, Hutchinson A, 'Environmental implications of the ongoing electrification of the UK light duty vehicle fleet'
Resources, Conservation and Recycling 174 (2021)
ISSN: 0921-3449AbstractPublished here Open Access on RADARThe light duty vehicle fleet in the UK is being electrified aggressively, with an ambitious target to ban the sale of all new internal combustion engine cars by 2030. At the same time, the electricity grid is also undergoing rapid decarbonization, potentially paving the way for a much greener use phase for electric vehicles. The paper presents a holistic prospective life cycle assessment of the environmental implications of these two interrelated transitions, while also considering an alternative scenario characterised by a gradual shift from traditional private vehicle ownership to shared mobility schemes. The results for both scenarios point to clear benefits in terms of reduced demand for non-renewable energy, carbon emissions and local air quality. However, a decisive behavioural shift towards shared mobility is shown to be crucial in order to offset the increased demand for Li, Co, Ni, Mn and Cu for electric vehicle power trains, and to avoid an otherwise potential increase in abiotic resource depletion and human toxicity impacts.
-
Kamran M, Raugei M, Hutchinson A , 'A dynamic material flow analysis of lithium-ion battery metals for electric vehicles and grid storage in the UK: Assessing the impact of shared mobility and end-of-life strategies. '
Resources, Conservation and Recycling 167 (2021)
ISSN: 0921-3449AbstractPublished here Open Access on RADARLimiting human-induced climate change represents a critical challenge for the future, and due to their disproportionate contribution to the problem, the energy and transport sectors are attracting the most attention in terms of emission reduction roadmaps and targets. Energy storage, particularly electrochemical storage, is poised to be a cornerstone in allowing those sectors to become more sustainable. This study presents the results of an integrated dynamic material flow analysis of the cumulative demand for lithium-ion battery metals (Li, Co, Ni and Mn) by the light duty vehicle and electricity generation sectors in the UK over the next three decades. Results have shown that recycling of end-of-life electric vehicle battery packs is very effective in “closing the loop”, and would enable driving the demand for all four metals back down to present levels by 2050, despite having achieved by then a complete shift to 100% electric vehicles. Additionally, repurposing end-of-life vehicle batteries for grid storage (with over 50 GWh of grid storage capacity expected to be in place by 2050) has been found to enable reducing purpose-built grid storage batteries to zero. Finally, an additional scenario analysis has indicated that a widespread behavioural shift from conventional vehicle ownership to shared mobility could even drive the demand for virgin battery metals into negative territory by 2040.
-
Raugei M, Kamran M, Hutchinson A, 'A prospective net energy and environmental life-cycle assessment of the UK electricity grid'
Energies 13 (9) (2020)
ISSN: 1996-1073 eISSN: 1996-1073AbstractPublished here Open Access on RADARNational Grid, the UK’s largest utility company, has produced a number of energy transition scenarios, among which “2 degrees” is the most aggressive in terms of decarbonization. This paper presents the results of a combined prospective net energy and environmental life cycle assessment of the UK electricity grid, based on such a scenario. The main findings are that the strategy is effective at drastically reducing greenhouse gas emissions (albeit to a reduced degree with respect to the projected share of “zero carbon” generation taken at face value), but it entails a trade-off in terms of depletion of metal resources. The grid’s potential toxicity impacts are also expected to remain substantially undiminished with respect to the present. Overall, the analysis indicates that the “2 degrees” scenario is environmentally sound and that it even leads to a modest increase in the net energy delivered to society by the grid (after accounting for the energy investments required to deploy all technologies).
-
KK Kumar, AR Hutchinson, JG Broughton, 'Static shear response of recycled carbon fibre composites for structural applications'
Composite Structures 246 (2020)
ISSN: 0263-8223 eISSN: 1879-1085AbstractPublished here Open Access on RADARThe specification and use of recycled carbon fibre composites require the generation of reliable data that gives a comprehensive description of the material. Our research dealt with an experimental study of recycled, discontinuous, needle-punched, non-woven carbon fibre/epoxy composites. The property-constituent relationships of these composites require the adaptation of testing practices, coupled with an understanding of their failure mechanisms. The objective was to define a test protocol to determine their shear load limits. Four interlaminar shear test methods were investigated, namely, Short Beam Shear, Double Notch Shear, Double Beam Shear and Iosipescu Shear. A modified Iosipescu shear specimen provided a stress state in the composite that was much closer to pure interlaminar shear than that observed with other test methods. Identification of the weakest shear plane and re-fabrication of the test geometry enabled consistent interlaminar shear failures using the Iosipescu test method. We found that the shear behaviour was dependent on the internal fibre architecture of our particular material, thus enabling potential optimisation of such composites.
-
Raugei M, Hutchinson A, Morrey D, 'Can electric vehicles significantly reduce our dependence on non-renewable energy? Scenarios of compact vehicles in the UK as a case in point'
Journal of Cleaner Production 201 (2018) pp.1043-1051
ISSN: 0959-6526 eISSN: 1879-1786AbstractPublished here Open Access on RADARElectric vehicles (EVs) are increasingly regarded as the way forward to deliver a much-needed improvement in the transport sector's sustainability profile, and the UK is embarking on a major transition towards them. While previous studies focused mainly on greenhouse gas (GHG) emissions, this article assesses the extent to which EVs may contribute to reducing the UK's dependence on (mostly imported) non-renewable primary energy. The study combines a life-cycle model of a compact battery electric vehicle (BEV) with a prospective energy analysis of a range of electricity supply alternatives for the vehicle's use phase. The key metric analysed is the non-renewable cumulative energy demand (nr-CED). Results show that, already under current conditions, the nr-CED of a compact BEV in the UK is lower by approximately 34% with respect to that of an otherwise similar internal combustion engine vehicle (ICEV). Such reduction is then expected to improve further under all future scenarios, indicating that a transition to EVs is indeed a recommendable option to reduce the UK's demand for non-renewable energy, especially if this is accompanied by a shift to a more renewable electric grid.
-
Hutchinson AR, Lui Y, Lu Y, 'Overview of disbonding technologies for adhesive bonded joints'
Journal of Adhesion 93 (10) (2016) pp.737-755
ISSN: 0021-8464AbstractThe ability to separate adhesive bonded assemblies without causing damage to the substrates is clearly very desirable. There are many applications such as in electronics, medical surgery, dentistry, building and general manufacturing where the opportunity to separate assemblies is important. This may be for repositioning in manufacturing, repair in service or recovery of materials at end-of-life. Various methods for adhesive reversibility or disbonding have been proposed over the last 40 years but there currently exist no universally accepted solutions for disbond-on-demand bonded applications. This paper considers the motivation for disbonding, the requirements and considerations associated with possible methods, and the overall effectiveness of the various mechanisms in the context of non-structural, semi-structural and structural joints. The range of technologies and mechanisms is reviewed, together with the associated methods for activation.Published here Open Access on RADARThe variety of methods is evaluated for their effectiveness in the context of different applications. Particular attention is given to the adverse effects on the performance of bonded assemblies in service, and the ways of mitigating these effects. It is shown that a total materials system approach must be adopted when seeking a disbonding technology for a particular set of circumstances.
-
Pausan N, Lui Y, Lu Y, Hutchinson AR, 'The use of expandable graphite as a disbonding agent in structural adhesive joints'
Journal of Adhesion 93 (10) (2016) pp.791-810
ISSN: 0021-8464AbstractExpandable graphite (EG) offers the potential to be used as a controllable adhesive disbonding mechanism in an adhesively bonded joint. The graphite particles can be incorporated, in small quantities, into the adhesive layer. Heat can be used to trigger the expansion and thereby facilitate disassembly of structurally bonded assemblies. An experimental programme was developed to investigate the engineering capabilities of different types of bonded joints, made with an epoxy and a polyurethane (PU) adhesive, containing different amounts of EG. The short- and long-term mechanical properties of lap shear and wedge cleavage joints were evaluated. In contrast to the incorporation of more conventional physical and chemical foaming agents into bondlines, typically in excess of a 10% addition level, it was found that the addition of just a few per cent of graphite was sufficient to provide a reliable disbonding mechanism. Moreover, the usual adverse side effects on joint performance, associated with incorporating functional additives, were far more limited.Published here Open Access on RADAR -
Raugei M, Morrey D, Hutchinson A, Winfield P, 'A coherent life cycle assessment of a range of lightweighting strategies for compact vehicles'
Journal of Cleaner Production 108 Part A (2015) pp.1168-1176
ISSN: 0959-6526 eISSN: 1879-1786AbstractPublished here Open Access on RADARA complete and fully consistent LCA-based comparison of a range of lightweighting options for compact passenger vehicles is presented and discussed, using advanced lightweight materials (Al, Mg and carbon fibre composites), and including all life cycle stages and a number of alternative end-of-life scenarios. Results underline the importance of expanding the analysis beyond the use phase, and point to maximum achievable reductions of environmental impact of approximately 7% in most impact categories. In particular, lightweighting strategies based on the use of aluminium were found to be the most robust and consistent in terms of reducing the environmental impacts (with the notable exception of a relatively high potential toxicity). The benefits of using magnesium instead appear to be less clear-cut, and strongly depend on achieving the complete phase-out of SF6 in the metal production process, as well as the establishment of a separate close-loop recycling scheme. Finally, the use of carbon fibre composites leads to similar environmental benefits to those achieved by using Al, albeit generally at a higher economic cost.
-
Clarke M, Broughton J, Hutchinson A, Buckley M, 'Application of the design of experiments procedure to the behaviour of adhesively bonded joints with plastically deformable adherends to enable further understanding of stain-rate sensitivity'
International Journal of Adhesion and Adhesives 44 (-) (2013) pp.226-231
ISSN: 0143-7496AbstractThe study presented in this paper was carried out to investigate further the effects of strain rate on the strength of adhesively bonded single lap shear joints. Tests were carried out on two different configurations of adhesively bonded joints that were designed to exhibit different behaviours. In one configuration both adherends were made from a relatively low strength grade of aluminium such that both would exhibit significant plastic deformation prior to adhesive failure. The other configuration used one adherend that was significantly stronger such that only elastic deformation was exhibited prior to failure of the adhesive. The joint specimens were tested at several different strain rates using a servo-hydraulic test machine and the results analysed using statistical methods. To further understand the results Finite Element models of the joints were created using a Cohesive Zone Model to predict damage development and failure in the adhesive. The Design of Experiments procedure was used to study the effects of material parameters relating to both the adherends and the adhesive in the Finite Element models. The results of the testing suggested that the strength of joints formed from two adherends that exhibited plastic deformation prior to failure did not show statistically significant sensitivity to strain rate. Interpretation of the results of the Finite Element analyses suggested that the adherend yield was the main factor influencing failure load in the adhesive for joints of this type.Published here -
McCurdy R, Hutchinson A, Winfield P, 'The mechanical performance of adhesive joints containing active disbonding agents'
International Journal of Adhesion and Adhesives 46 (2013)
ISSN: 0143-7496AbstractA controllable adhesive disbonding mechanism can be achieved by incorporating, and then activating, functional additives located within the matrix of an adhesively bonded joint. This action facilitates the disassembly and material recovery of structurally bonded assemblies.The engineering capabilities of bonded joints containing a range of chemical or physical foaming agents were investigated. Joint disassembly was measured as a function of additive chemistries, physical properties and concentration. The short- and long-term mechanical properties of bonded joints and bulk adhesives containing functional additives were subsequently evaluated.The disbonding mechanism was found to be due to a ‘solid-state foaming’ of the adhesive, followed by a proliferation of micro-cracking throughout the matrix. The effect of the physical foaming agents on joint disassembly was mostly attributable to the volumetric expansion efficiency of the additive whilst constrained within an adhesive matrix. For chemical foaming agents, the effectiveness of disassembly was dependent on the chemical compatibility of the adhesive and additive, the concentration and the efficiency to which the additive decomposed to a gas.Published here Open Access on RADAR -
Clarke M, Broughton J, Hutchinson A, Buckley M, 'An investigation into the use of an embedded-process zone model for predicting the structural behaviour of adhesive bonded joints'
International Journal of Vehicle Structures and Systems 3 (3) (2012) pp.203-209
ISSN: 0975-3060AbstractPublished hereThe study presented in this paper was carried out to assess the use of an embedded process zone based model in a commercial finite element code for predicting the behaviour of adhesively bonded structures. The relevant adhesive properties were measured using a variety of test methods and the results applied to the analysis of a single lap joint. Having demonstrated satisfactory accuracy in simulating the behaviour of the single lap joint the same methodology was then applied to a more complex structure. The structure used was a T shaped structure formed from two adhesively bonded aluminium rails. Despite some variability in the test results acceptable correlation with the analysis results was again achieved. The effects of variability in the adhesive material data on the output from the Finite Element analysis were investigated using a statistical study. This showed only a limited sensitivity to the interface toughness parameter
-
Hooper M, Hutchinson A, Broughton J, Taylor M, 'Development of a novel test rig for the evaluation of aircraft fuel tank sealant'
Journal of Testing and Evaluation 40 (1) (2012) pp.1-7
ISSN: 0090-3973AbstractA key concept for the future evaluation of sealant materials for commercial aircraft is to expose realistic sealed joint systems to typical dynamic and environmental parameters representative of actual flight conditions. The development of a mechanism to undertake the full range of test parameters for the evaluation of sealants for current and future aircraft is described in this paper. This mechanism, or model sealed system (MSS), consists of an axial stress machine into which vibrational fatigue, high and low temperatures and pressures can be programmed for automatic operation. The test coupons, within the MSS, can be stressed to simulate flight conditions along with the flight pressures and temperatures. The MSS is described and the results of sealant evaluation to date are presentedPublished here -
Sweeting W, Hutchinson A, Savage S, 'Factors affecting electric vehicle energy consumption'
International Journal of Sustainable Engineering 4 (3) (2011) pp.192-201
ISSN: 1939-7038AbstractPublished hereInternal combustion (IC) engines waste a majority of the energy they consume, with only 20% actually going into moving the vehicle. The drivetrains of electric vehicles (EVs) can operate at over 80% efficiency which shows that they have great potential in reducing the transportation energy demand. This paper initially quantifies the energy needed to run an EV, having similar dimensions and performance to modern IC vehicles. Simple range and cost calculations were used to establish the advancements needed in battery technology to match the ranges of IC vehicles. Factors affecting EV energy consumption are then addressed, with the aid of MATLAB® simulations, to ascertain what variations can be expected in real-world situations and the benefits of optimising vehicle parameters. The results are then compared with conventional and hybrid IC vehicles. It is shown that an optimised EV can achieve a 63%"tank-to-wheels" energy reduction over the best conventional IC vehicles available, and 60% over hybrids. The effects of either a badly optimised EV, hard acceleration during the driving cycle, or constant large accessory power draws, such as heaters and demisters, are each shown to increase the EVs energy consumption by 70%/km. To achieve the performance and practicalities comparable with modern IC vehicles, new battery technologies with specific energies of >300 Wh/kg are required.
-
Hutchinson A, Winfield P, McCurdy R, 'Automotive material sustainability through reversible adhesives'
Advanced Engineering Materials 12 (7) (2010) pp.646-652
ISSN: 1438-1656AbstractPublished here Open Access on RADARThis communication defines the key existing technologies for reversible adhesion and bonded joint disassembly, and introduces the reader to early experimental findings on the use of thermally labile functional additives in an adhesive matrix. These additives have been found to induce localized, out of plane stresses in a joint's bondline, allowing for an adhesive disbond. It has been found that the additive and adhesive matrix combination is key to the relationship between joint disassembly and joint strength.
-
Fessel G, Broughton J, Fellows N, Durodola J, Hutchinson A, 'Fatigue performance of metallic reverse-bent joints'
Fatigue and Fracture of Engineering Materials and Structures 32 (9) (2009) pp.704-712
ISSN: 8756-758XAbstractPublished hereAdhesively bonded lap shear joints have been investigated widely and several ideas have been proposed for improving joint strength by reducing bondline stress concentrations. These include application of adhesive fillets at the overlap ends and use of adhesive with graded properties in the overlap area. Another, less common, approach is to deform the substrates in the overlap area in order to obtain a more desirable bondline stress distribution. Previous work carried out by the authors on a number of different substrate materials indicated that a reverse-bent joint geometry is useful for increasing joint strength. Results from static stress analysis and experimental testing demonstrated that significant improvements could be achieved. This paper presents results of further work carried out to assess the fatigue performance of reverse-bent joints. Substrates with different yield and plastic deformation characteristics were used and the effects of different overlap lengths on strength were examined. The results of this research show that the improvements obtained under static tests conditions translate to even higher benefits in fatigue. The paper also explains the failure mechanism of the joints under fatigue loading.
-
Custódio J, Broughton J, Cruz H, Hutchinson A, 'A review of adhesion promotion techniques for solid timber substrates'
Journal of Adhesion 84 (6) (2008) pp.502-529
ISSN: 0021-8464AbstractThe use of primers, coupling agents, and other surface treatments to enhance adhesion is now common in the aerospace, automotive, and plastics industries, where they are used to develop highly durable bonds to metals, advanced composites, ceramics, and plastics. However, such treatments are virtually non-existent in the wood products industry although they could solve important adhesion problems. In particular, adhesion promoters can enhance the environmental durability of epoxy bonded joints, and they can enhance the reliability of bonds to timber treated with wood preservatives. A review of current findings is provided that attempts to gather the scarce and disperse information available in the literature about adhesion promotion techniques for bonded solid timber joints. A general overview of the research needs on this topic is also given.Published here -
Rahimi H, Hutchinson A, 'Concrete Beams Strengthened With Externally Bonded Frp Plates'
Journal of Composites for Construction 5 (2001) pp.44-56
ISSN: 1090-0268 eISSN: 1943-5614 -
Salamat-Zadeh F, Allen KW, Winfield PH, Hutchinson AR, 'Self-hot-melt Joining of Polymers to Lacquered Metal Surfaces'
International Journal of Adhesion and Adhesives 20 (2) (2000) pp.123-134
ISSN: 0143-7496AbstractMetal cans represent the dominant form of packaging in the food and beverage markets. Organic coatings i.e., lacquers, are applied to the inside of the cans to prevent undesirable interactions. The most common lacquer is based upon epoxy–phenolic materials.Published hereAdvances in packaging technology have directed a requirement for the non-adhesive attachment of thermoplastic compounds, lids and fixtures such as gas capsules “Widgets” to the coatings of metal cans. This represents a new challenge and requires adaptation of the joining techniques currently available.
This paper examines the joining of thermoplastic materials to epoxy–phenolic-lacquer-coated tin-free steel. A range of thermoplastics was characterised by their mechanical, thermal and surface energetic properties. A particular joining technique was then developed involving the simultaneous heating and pressing of the coated metal against the thermoplastic component. The process parameters of temperature, pressure and time were evaluated in terms of the properties of the bond. The mechanical behaviour of different types of peel joint was investigated, together with the influence of the moisture content of the thermoplastics.
-
Hutchinson A, Pagliuca A, 'Ms Sealants: a Comparative Study of Performance Properties'
Adhesives Age 39 (1996) pp.16-&
ISSN: 0001-821X
Books
-
Hutchinson AR, Morrey D, Guide to energy and publicly-accessible transport in rural areas, Oxford Brookes University (2015)
ISBN: 978-1-873640-88/3Published here -
Winfield P, Hutchinson A, Pemberton M, Whole life vehicle waste streams - a global perspective, Oxford Brookes University (2007)
ISBN: 978-0955625411
Book chapters
-
Hutchinson AR, Broughton JG, 'Adhesives' in Doran DK, Cather R (ed.), Construction Materials Reference Book, 2nd edition, Routledge (2013)
ISBN: 978-0-7506-6376-2AbstractChapter 31 -
Hutchinson A, Winfield PH, Morrey D, 'Automotive Structures: Design for Disassembly and the Role of Adhesive Bonding' in Stone I, McKay B, Fan Z (ed.), Automotive Structures: Design for Disassembly and the Role of Adhesive Bonding, Trans Tech Publications Ltd (2013)
AbstractA controllable adhesive disbonding mechanism can be achieved by activating functional additives located within the matrix of an adhesively bonded joint. This action facilitates the disassembly and material recovery from structurally bonded assemblies. The engineering capabilities of bonded joints containing a range of physical foaming agents were investigated. The effect of the physical foaming agents on joint disassembly was mostly attributable to the volumetric expansion efficiency of the additive whilst constrained within an adhesive matrix.Published here -
Hutchinson A, 'Adhesives for externally-bonded FRP reinforcement' in ICE Manual of Construction Materials. Volume II, Thomas Telford (2009)
ISBN: 9780727735973AbstractExternally bonded fibre-reinforced polymers (FRP) reinforcement represents one of the fastest-growing applications of polymer composites in construction. Adhesives are used to transfer shear stresses across the interface between the parent material(s) and the composite reinforcement. The principles and requirements associated with adhesive bonding are reviewed in the context of strengthening applications involving concrete, metallic and timber structures.Published here -
Hutchinson A, 'Selection of foam back-up material for use in sealed joints in cladding and curtain walling' in Handbook of Sealant Technology, Routledge (2009)
ISBN: 9780849391620AbstractSealing is an age-old problem that dates back to our earliest attempts to create a more comfortable living environment. Prehistoric people used natural sealants such as earth, loam, grass, and reeds to protect the interior of their homes against the weather. Today's applications extend to a myriad of uses. The Handbook of Sealant Technology provides an in-depth examination of sealants, reviewing their historical developments and fundamentals, adhesion theories and properties, and today's wide range of applications. Featuring contributions from international academic and industry experts, this comprehensive, illustrated reference explores: •The history of sealants from the Stone Age to the present •The testing and durability of sealants and sealed joints •The use of organofunctional silanes in sealant technology •Hot melt and intumescent sealants •Urethane waterproofing membrane systems •Foam back-up materials •Sealants for use in construction, bridge expansion joints, and automotive electronics •Fibrin sealants for biomedical applications As technology continues to develop, the potential for sealant use grows exponentially. This valuable reference guide provides a window on the past and offers insight into the extent of future possibilities in a host of industries. -
Hutchinson A, 'Surface preparation of component materials' in Strengthening and rehabilitation of civil infrastructures using fibre-reinforced polymer (FRP) composites, Woodhead Publishing (2008)
ISBN: 9781845694487
Conference papers
-
JG Broughton, AR Hutchinson, P Winfield, 'Dismantlable Adhesive Joints For Decommissioning, Repair and Upgrade'
(2018)
ISBN: 9789283721727AbstractAdhesive bonding is well established as one the most successful means of joining advanced composite materials, which are increasingly employed to reduce weight and extend service life. It is also well known that adhesives used to sustain structural loads tend to be permanent, cross-linked and irreversible, which raises particular challenges when equipment becomes obsolete or when there is a need for upgrade or repair. This paper reviews the latest published work on dismantlable adhesive technologies, and highlights the criteria needed to evaluate potential disbondable systems. Whilst tailored formulations, originally developed as selfhealing polymers, demonstrate considerable promise for self-repair, re-adjustment and disbonding, it concludes that additives, in the form of expandable reactive agents, offer demonstrable performance and relatively simple adaptation to bonding technology currently employed. These, in conjunction with appropriate design strategies in order to aid design for disassembly, should offer potential solutions for innovation in temporary repair and upgrade scenarios, including adaptive armour or the development of new modular design platforms using advanced composites.Open Access on RADAR -
Pagliuca A, Hutchinson A, 'Adhesion Properties of Sealants in Resealed Joints'
(1996) pp.109-128
Other publications
-
Savage SD, Winfield PH, Hutchinson AR, 'The State of Global End-of-Life Vehicle Recycling legislation', (2010)
-
Pemberton MJ, Winfield PH and Hutchinson AR, 'World Auto Report-2008', (2009)