Decarbonisation of Welding and Associated Processes in the fabrication of large steelwork structures - supported by BAE Systems iCASE award

Manufacturing causes 20% of carbon emission globally and consumes about 54% of global energy generation – this means large scale manufacturers need to understand and address their carbon emission for effective decarbonisation of manufacturing processes. Effective measurement of sustainability, reporting and prioritisation were identified as crucial barriers towards effective decarbonisation.

This challenging and rewarding iCASE award will effectively investigate and report the energy consumption across different manufacturing processes in the Barrow site of BAE Systems. The project will span across Energy and Sustainability and Manufacturing themes of Cranfield University and would be rewarding as it will endeavour to establish the carbon emission measuring, reporting and prioritisation principles which has the potential to shape the future of manufacturing.

The multi-disciplinary studentship would be awarded for a Cranfield University PhD research project into reducing the carbon footprint of welding processes in the fabrication of large steelwork structures. This project will combine the research disciplines of Manufacturing and Sustainability to develop a novel approach to minimise the carbon footprint of welding and associated processes while at the same time improving the quality and productivity of the welding outputs. The project will contribute to BAE Systems ambitious Carbon Net Zero targets which aims to realise a Carbon Net Zero Barrow site and facilities by 2030.

A novel optimisation tool will be developed to build least-cost pathways for Welding and Associated Processes in the fabrication of large steelwork structures. This tool will include a balanced and coherent approach to significantly reducing energy consumption while considering the wider business goals of productivity, cost, quality etc. This tool will consider a range of in-house and off-the-shelf welding techniques and processes and innovative net zero interventions.

Work-packages/objectives of the programme are as given below;

• Develop an understanding of the existing Welding techniques and associated processes energy consumption footprint.
• Develop a Balanced Scorecard approach to evaluate the Carbon Footprint verse business implications of pursing a welding net zero strategy.
• Down select a steelwork structure and welding process(s) that to be used for manufacture.
• Validate Balanced Scorecard tool based on data generated from instrumented welding to manufacture the component.
• Work with Manufacturing and SHE teams to implement chosen technology solutions and demonstrate the application of the tool using a specific welding and associated processes.

The successful candidate will attend Cranfield University’s research student training programme which is designed to equip students with research and other transferrable skills required during their research studies and in their future careers.

• Application deadline29 Nov 2023
• Award type(s)PhD
• Start dateAs soon as possible
• Duration of award4 years
• EligibilityUK
• Reference numberSATM397

Applicants should have a 1st or 2.1 UK degree or equivalent in a related discipline, such as mechanical engineering, chemical engineering, materials, chemistry or physics. The ideal candidate should have some understanding in manufacturing and sustainability. The candidate should be self-motivated, have good communication skills, for regular interaction with other stake holders, with an aptitude for industrial research.

The studentship is sponsored by iCASE award and the student will receive a tax free bursary of £20k p.a. plus the fee (in an EU rate) will be paid. To be eligible for funding, the applicants must have UK citizenship.

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.