PhD Studentship: Developing Multi-Material Structures using Additive Manufacturing

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Engineering
Location:  UK Other
Closing Date:  Sunday 10 March 2024
Reference:  ENG1730

This project is an exciting opportunity to undertake industrially linked research in partnership with the Manufacturing Technology Centre (MTC). It is based within University of Nottingham at the Centre of Additive Manufacturing.  This is 3-year fully funded studentship is only open to UK home students. The successful applicant will receive a generous tax-free annual stipend of £26,658 plus payment of their full-time home tuition fees. Due to funding restrictions this PhD position is only available to UK nationals. As this position is sponsored by the MTC, any successful candidate would need to pass the sponsors own security checks prior to the commencement of the PhD.

Vision

The vision for next-generation Additive Manufacturing (AM) is to control the chemical composition of every single deposited volume to realise functional materials (FMs) directly from digital designs. While polymeric FMs can be realised easily via various commercial techniques, there remains a significant challenge for the realisation of FMs made of metallic materials. Metallic FMs have attracted interest in a variety of industrial fields, especially in energy (batteries, electric motors, etc.), transport (heat exchangers, actuators, crash boxes, etc.), and defence. These FMs could replace assemblies that are currently made by joining multiple components and could also significantly enhance part performance by engineering the mechanical and physical properties at small scale.  This will also lead to the creation of new architected materials (also known as metamaterials), which have properties beyond those accessible with the current range of metal alloys.

Aim

The objective of this PhD project is to address the knowledge gap around metallic FMs and establish new methods for multi-metal AM. This requires the identification of suitable material combinations for laser-based AM and the determination of appropriate design guidelines for the interfaces formed between dissimilar materials. For the success of metallic FM, there is a critical need to understand how different metals can be combined in AM to achieve desired properties. To achieve this, the project will focus on determining the structural and thermal behaviour of the interface regions of the printed component, where dissimilar materials are in contact. This will be done by studying the printing laser parameters' effect on these regions. Similarly, it is essential to understand how different material distributions at the interface (sharp distribution, diffused, interlocked, etc.) affect the robustness of the joint. The correct design of these complex parts will require characterizing and testing the interfaces formed in the printed structures. 

The project builds on the Centre for Additive Manufacturing (CfAM)'s expertise in applying computational materials science techniques to laser AM to identify and select suitable material combinations. State-of-the-art AM software will be used to design parts with the identified materials to satisfy the desired properties of the final product. In addition, the PhD candidate will be able to conduct research using a state-of-the-art multi-beam laser powder bed fusion platform equipped with a multi-metal deposition system, for selective material deposition in a single layer (a one-of-a-kind facility in the UK).

The PhD student will develop these structures using a combination of AM and metrology techniques, advanced materials testing, microscopy, and numerical modelling, gaining a broad set of skills and knowledge relevant to advanced manufacturing and materials research. The student will work as part of a dynamic interdisciplinary team at CfAM, one of the world's largest research centres for additive manufacturing and 3D printing, to advance the state-of-the-art in this field. This research has the potential to pave the way for new and exciting applications of AM in various industries, improving product performance and reliability.

Who we are looking for

• A first or upper-second-class degree in an engineering or materials science discipline 
• A driven individual with an inquisitive mind.
• Ability to produce high-quality presentations and written reports.

The MTC is an independent Research and Technology Organisation (RTO) aimed at de-risking and accelerating the adoption of disruptive technologies within the UK manufacturing sphere. Supported by the UK government, the MTC works closely with industrial partners and other research organisations to deliver world leading innovation across all levels of the UK’s industrial landscape, from SMEs and start-ups to OEMs and large-scale global manufacturers. For more information please visit the MTC website . 

The Faculty of Engineering provides a thriving working environment for all PGRs creating a strong sense of community across research disciplines. Community and research culture is important to our Postgraduate Researchers (PGRs) and the FoE support this by working closely with our Postgraduate Research Society (PGES) and our PGR Research Group Reps to enhance the research environment for PGRs. PGRs benefit from training through the Researcher Academy’s Training Programme, those based within the Faculty of Engineering have access to bespoke courses developed for Engineering PGRs. including sessions on paper writing, networking and career development after the PhD. The Faculty has outstanding facilities and works in partnership with leading industrial partners. 

Contact

Informal inquiries, with a detailed CV and academic transcripts, should be sent to Dr Marco Simonelli ([email protected] ). Prof. Chris Tuck ([email protected]) and Dr. Amanda Crutchley ([email protected] ).

Proposed PhD Start Date: 1st October 2024.