Developing a Ground breaking Wire-Directed Energy Deposition (w-DED) Technology for Printing Ultra-Thin Walls, Intended for Application in High-Tech Sectors

This PhD project aims to develop a ground breaking wire-directed energy deposition (w-DED) technology for printing ultra-thin walls, intended for application in high-tech sectors such as healthcare, electronic devices, automotive, and aerospace.

Micro-scale parts/components find extensive use in sectors such as healthcare, electronics, automotive, and aerospace. Currently, one of the innovative manufacturing processes for producing them is metal additive manufacturing (AM), primarily utilizing powder bed processes.

Wire-based Directed Energy Deposition (w-DED) is a pivotal AM process alongside the powder bed process. In comparison with the Laser powder bed AM process, w-DED surpasses in its capability to print dimensions without limits, offering higher deposition rates, improved metallurgy, greater feedstock material efficiency, and reasonable investment costs. However, conventional w-DED processes suffer from low resolution (high surface waviness) due to the nature of w-DED processes, characterized by high heat input and challenges in maintaining droplet transfer and melt pool formation stability. Therefore, printing micro-scale parts/components poses a significant challenge for w-DED processes. To overcome this challenge, we have proposed a novel w-DED process, primarily focused on developing a unique torch integrated with an innovative feedstock material system for printing ultra-thin walls (less than 1.0 mm, potentially around 0.4-0.6 mm).

In this project, in addition to developing the novel w-DED process, the PhD student will collaborate with advanced facilities, including a high-speed video camera system, laser illumination, and others at the Welding and Additive Manufacturing Centre. This collaboration aims to deepen our understanding and knowledge by investigating the fundamental mechanisms of arc plasma, droplet transfer, and melt pool behaviour.

• Application deadline08 Nov 2023
• Award type(s)PhD
• Start dateAs soon as possible
• Duration of award3 years
• EligibilityUK, Rest of World, US, EU
• Reference numberSATM392

Applicants should hold a first- or second-class UK honours degree or its equivalent in a related discipline, such as mechanical engineering, materials science and engineering, welding, or additive manufacturing. The candidate should be self-motivated and possess excellent experimental, reporting, and communication skills.

Self-funded PhD opportunity open to UK, EU and international students. The cost for running experiments and accessing to research facilities will be supported by the Welding and Additive Manufacturing Centre.

Research students at Cranfield benefit from being part of a dynamic, focused and professional study environment and all become valued members of the Cranfield Doctoral Network.  This network brings together both research students and staff, providing a platform for our researchers to share ideas and collaborate in a multi-disciplinary environment. It aims to encourage an effective and vibrant research culture, founded upon the diversity of activities and knowledge. A tailored programme of seminars and events, alongside our Doctoral Researchers Core Development programme (transferable skills training), provide those studying a research degree with a wealth of social and networking opportunities.

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If you are eligible to apply for this studentship, please complete the online application form.