Developing novel micro-casting and solidification processes that enable the use of recycled materials as high quality feedstock for metal additive manufacturing (MAM)

An exciting opportunity for a full-time PhD scholarship (fully funded) in Sustainable Manufacturing Processes is now available at the Sustainable Manufacturing Systems Centre in collaboration with the Welding and Additive Manufacturing Centre of Cranfield University. 

We are looking for an exceptional candidate with background in materials, metallurgy, manufacturing, engineering, physics or similar. The successful candidate will receive a bursary of up to £19,000 (tax free), tuition fees for three years and access to office and laboratory space.

Metal additive manufacturing (MAM) has recently emerged as a disruptive set of processes for manufacturing high-value components with lower environmental fingerprint compared to conventional subtractive manufacturing. Furthermore, the use of recycled materials as feedstock in MAM processes can offer significant environmental and economic benefits. However, recycled feedstock is often considered of lower quality compared to virgin ones, that may have a negative impact on the integrity and mechanical performance of the manufactured parts. 

This PhD studentship will focus on developing processes which will enable the use of recycled swarf in metal additive manufacturing while maintaining highest standards for structural integrity and properties for the manufactured parts. The project will investigate micro-casting processes with swarf as feedstock using arc melting (and/or laser melting) a) as an integrated part of a liquid filling in process and b) for manufacturing wires for wired-based additive manufacturing processes (eg WAAM). Parameters such as energy input arc pressure and heat transfer efficiency on the melting rate and the liquid metal properties will be analysed. Computational Fluid Dynamics (CFD) models will be developed to optimize the process. The microstructure and properties of intermediate products (eg wires) and manufactured parts will be investigated. The project will focus primarily on aerospace materials including titanium alloys, nickel superalloys and steels.

The PhD student will be based at the Sustainable Manufacturing Systems Centre at Cranfield University and will have the opportunity to travel within and outside UK for professional meetings, industrial visits and present research findings regularly to scientific conferences and workshops.

The project will offer opportunities to develop core skills in various research areas including process development and modelling, material characterisation, environmental & economic assessment. The student will have access to specialized facilities on casting and solidification, additive manufacturing, materials characterisation, simulation tools, and will have the opportunity to collaborate with a team of academics, researchers and technical staff.

The project would well suit students with Materials Science, Physics, Aerospace Engineering or Mechanical Engineering background who are interested in Sustainable Manufacturing and Advanced Metals Processing.

This PhD studentship is aligned with the project “Sustainable Additive Manufacturing” supported by EPSRC. The project aims to develop Novel metal AM processes that utilise recycled swarf as feedstock, enabling a greatly reduced overall energy and CO2 footprint for high-value near-net-shaped components, and facilitating much wider exploitation of near-net-shape AM technologies throughout industry.

• Application deadline26 Apr 2023
• Award type(s)PhD
• Start date05 Jun 2023
• Duration of award3 years
• EligibilityUK
• Reference numberSATM358

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.

For further information please contact:

Name:   Dr Konstantinos Georgarakis
Email:    [email protected]
T: (0)1234 750111 Ext: 50202

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