DIGI-HSMC · Digital High-Shear Melt Conditioning for Resource-Efficient Aluminium Processing
DIGI-HSMC

Digital High-Shear Melt Conditioning for Resource-Efficient Aluminium Processing

Connecting physical melt conditioning with sensing, monitoring and a physics-informed digital twin.

UKRI Innovate UK Funded by Innovate UKInnovate UK Project No. 10183007
PROJECT PERIOD July 2026 – March 2027
DIGI-HSMC SYSTEM CONCEPT CONCEPTUAL ILLUSTRATION
Conceptual illustration of the DIGI-HSMC system Cross-section of a refractory-lined melt vessel with a drive, shaft and rotor–stator assembly creating a high-shear zone and recirculating flow in the melt. Sensing points on the probe, drive and vessel wall feed a data bus into unified monitoring, a physics-informed digital twin of the vessel, and a qualitative operator view. A dashed return path shows operator adjustment of the conditioning process. Illustrative only; no measured values are shown. PHYSICAL LAYER SENSING + DIGITAL LAYER SENSING UNIFIED MONITORING PHYSICS-INFORMED DIGITAL TWIN GEOMETRYFLOW FIELDPROCESSPHYSICS OPERATOR VIEW · QUALITATIVE PROCESS STATEINTERPRETATIONOPERATOR INSIGHT OPERATOR ADJUSTMENT DRIVE MELT ROTOR–STATOR HIGH-SHEARZONE REFRACTORYLINING
Physical layer Sensing and digital layer Operator adjustment QUALITATIVE · NO MEASURED VALUES SHOWN

01 · INDUSTRIAL CHALLENGE

Melt quality is a process-control challenge

In aluminium casting and recycling, the condition of the melt affects what happens downstream. When melt quality is variable and difficult to observe directly, operators must make decisions with incomplete information. That uncertainty is typically managed through longer holding, re-processing or rejection, each of which carries a material and energy cost.

  1. STAGE 1 →

    Melt variability

    Input material, composition and melt history differ between batches.

  2. STAGE 2 →

    Melt-quality challenges

    Variability shows up as differences in melt quality ahead of casting.

  3. STAGE 3 →

    Process uncertainty

    Limited visibility of melt condition makes process decisions harder.

  4. STAGE 4 →

    Holding, re-processing, rejection

    Uncertainty is managed conservatively, at the furnace or after casting.

  5. OUTCOME

    Additional material and energy burden

    The cost of uncertainty is paid in energy, time and metal.

02 · DEFINITION

What is DIGI-HSMC?

DIGI-HSMC is an Innovate UK-funded research and development project developing an integrated approach to High-Shear Melt Conditioning for resource-efficient aluminium processing, combining physical melt conditioning with sensing, monitoring and a physics-informed digital twin.

What is High-Shear Melt Conditioning?

High-Shear Melt Conditioning (HSMC) is a melt treatment approach in which a rotor–stator device applies intensive shear to liquid aluminium before casting. DIGI-HSMC develops this physical process together with the sensing and digital layers needed to observe and interpret it.

PROJECT RECORD
TYPE
Research and development project
FUNDER
Funded by Innovate UK
PROJECT NO.
10183007
PERIOD
July 2026 – March 2027
CONSORTIUM
Zyomax Limited; BCAST, Brunel University of London; International Syalons (Newcastle) Limited; Aeromet International Limited
DOMAIN
Aluminium melt conditioning and processing
PHYSICAL LAYER High-Shear Melt Conditioning
INFORMATION LAYER Sensing & Monitoring
DIGITAL LAYER Physics-Informed Digital Twin
ONE INTEGRATED SYSTEM DIGI-HSMC

03 · THE TECHNOLOGY

Three technologies.
One integrated system.

Three technical layers are developed together as one project architecture.
Each layer depends on the one below it; none is positioned as a stand-alone product.

01 PHYSICAL

High-Shear Melt Conditioning

A rotor–stator assembly applies intensive shear to the aluminium melt. This is the physical process the rest of the system is built to observe and interpret.

02 INFORMATION

Sensing & Monitoring

Process sensing captures signals from the melt and conditioning equipment. Monitoring brings those signals together into one consistent view of the process.

03 DIGITAL

Physics-Informed Digital Twin

A digital representation of the process that interprets monitored data against the physics of melt conditioning, so operators can see what the measurements mean.

DEVELOPED TOGETHER WITHIN DIGI-HSMC Explore the Technology

04 · HOW IT WORKS

A closed information loop with the operator in it

DIGI-HSMC links the physical process to measurement, interpretation and an operator decision. The operator remains responsible for adjusting the process. The system is not described as autonomous control.

  1. MEASURE Sensor capture Signals are captured from the melt and the conditioning equipment.
  2. MEASURE Unified monitoring Signals are brought together into one monitoring layer.
  3. UNDERSTAND Digital twin computation The physics-informed digital twin interprets the monitored data.
  4. UNDERSTAND Operator dashboard Interpreted process information is presented to the operator.
  5. ADJUST · HUMAN DECISION Operator adjustment The operator decides whether and how to adjust the conditioning process.

BACK TO SENSOR CAPTURE

05 · DEVELOPMENT PATHWAY

From research technology to industrial application

DIGI-HSMC is developing the technical foundations for future industrial application by integrating physical melt conditioning, process sensing, monitoring and a physics-informed digital twin.

{{ s.tag }} {{ s.label }} {{ s.desc }}

Potential industrial relevance

Future deployment depends on the outcome of testing and technical validation. The areas below describe where the approach is intended to apply, not where it is in use today.

  • Aluminium foundries
  • Aluminium recyclers
  • Melt-treatment operations
  • Casting environments
  • Industrial process development
  • Future technology integration

06 · WHY IT MATTERS

Toward more resource-efficient aluminium processing

PROJECT TARGET EVIDENCE LEVEL 3

10–20%

Potential reduction in furnace holding time

Target, not yet a verified DIGI-HSMC result.

INTENDED CONTRIBUTION 01

ENERGY & EMISSIONS

Furnace holding consumes energy. Better visibility of melt condition is intended to support shorter, better-informed holding decisions.

INTENDED CONTRIBUTION 02

RESOURCE EFFICIENCY

The project aims to reduce the re-processing and rejection that follow from uncertain melt quality.

INTENDED CONTRIBUTION 03

RECYCLING & CIRCULARITY

Melt conditioning has potential relevance to processing recycled aluminium, where input material can vary more between batches.

07 · EVIDENCE STANDARD

Built around evidence, not assumptions

Every claim on this site carries one of four maturity markers, so it is always clear what is background, what is prior research, what is a target and what has been verified.

  1. LEVEL 1

    INDUSTRY CONTEXT

    Established background about aluminium processing in general. Describes the problem space, not DIGI-HSMC.

  2. LEVEL 2

    PRIOR RESULT

    Findings from earlier HSMC or prototype research. Relevant context, but not a result of this project.

  3. LEVEL 3

    PROJECT TARGET

    What DIGI-HSMC aims to achieve. A target describes intent, not achieved performance.

  4. LEVEL 4

    VERIFIED DIGI-HSMC RESULT

    Measured within this project and confirmed through validation.

Prior HSMC result ≠ DIGI-HSMC result

Project target ≠ achieved performance

How the project will validate results →

08 · PROJECT DEVELOPMENT

Building the technology through development and validation

  1. {{ p.kicker }} {{ p.label }} CURRENT PHASE

Phases are shown in sequence. Validation has not yet been completed. Project objectives →

09 · CONSORTIUM

Four organisations. One integrated R&D programme.

About the consortium →
  • Zyomax Limited
    LEAD · SYSTEM INTEGRATION Zyomax Limited
    Project lead and HSMC technology / system integration expertise.
  • BCAST, Brunel University of London
    PARTNER BCASTBrunel University of London
    Research and materials / process expertise.
  • International Syalons (Newcastle) Limited
    PARTNER International Syalons(Newcastle) Limited
    Advanced ceramic engineering and silicon nitride expertise.
  • Aeromet International Limited
    PARTNER Aeromet International Limited
    Industrial application and validation expertise.

10 · RELEVANCE

Could the approach be relevant to your melt process?

We are interested in technical conversations about process conditions, constraints and where better visibility of melt condition could help.

  • Aluminium foundries
  • Aluminium recyclers
  • Process engineers
  • Technical managers
  • Technology developers
  • Research organisations
  • Industrial collaborators

THE APPROACH MAY BE RELEVANT WHERE

  1. 01Melt quality is managed through extended holding time.
  2. 02Re-processing or rejection follows from uncertain melt condition.
  3. 03Recycled input increases batch-to-batch variability.
  4. 04Visibility of melt condition ahead of casting is limited.

DISCUSS YOUR MELT PROCESS

Could DIGI-HSMC be relevant to your melt process?

We welcome technically relevant enquiries from aluminium processors, recyclers, researchers, technology organisations and potential industrial collaborators interested in the development and future application of High-Shear Melt Conditioning.