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This paper is a composite. It describes research performed initially in Singapore on the
integrity of lightweighting (magnesium) alloys and on the sustainability of industrial
systems. The work is based upon an approach to engineering integrity and plant
operations which incorporates the concept of Industrial Ecology. The first stage of the
research was undertaken within an international consortium "Precision Processing of
Ultra-Light Alloys and Composites" (PULAC) in Nanyang Technological University and
GINTIC, Singapore. Initially this involved studies of lightweighting and enhanced
recyclability of engineering cast components for microelectronics and vehicles, focussing
on structural integrity and high-pressure die-casting of magnesium alloys. The work then
took a new departure in the arena of simulation and modelling. Several case studies were
undertaken including the processes of a complete metal supply chain. It involves a pilot
plant in Australia (ILM) and a die casting company in Singapore (DYNACAST). The
research work has further evolved via a programme at University College Cork within the
new Environmental Research Institute -- with a focus on cleaner production,
environmental security and industrial sustainability. The paper is organized into three
main sections. The first section describes fatigue, fracture and stress-corrosion research
on high-pressure die cast magnesium alloy specimens. The second section describes
research on the simulation and modelling of industrial processes, which focuses on the
sustainability of the light metals industry. The third section describes how the work
might evolve through current research developments at the Environmental Research
Institute of University College Cork, Ireland. The general idea is to look at the overall
integrity of the various projects as a "retrospect and prospect" and to generate this theme
for future research and development, as a discussion paper for this Conference.