Corewire Ltd manufacture flux-cored wire welding consumables. They also manufacture equipment which uses these wire consumables to repair and resurface a variety of high wear resistance steel components. This includes dies for the manufacture of automotive components and rolls used in the production of rolled metal.
This project will explore how this current technology and capability can be evolved into additive manufacturing of full components. A key thread will be establishing and quantifying the specific challenges to moving from resurfacing by depositing a few layers of weld metal to full component manufacture using tens or even hundreds of layers. The project will therefore commence with the deposition of current resurfacing solutions (first six months) and progress with the manufacture of increasingly challenging steels and prototypical components. The challenges include higher performance steels, increased reinforcement, compositional grading, more complex geometry, etc. The research programme will include microstructural characterisation, experimental stress-strain measurement, modelling of stress-strain accumulation during additive manufacture and alloy development. High wear resistance steels will be the focus of the research programme and the research is likely to include some wear evaluation and fracture toughness testing.
Alongside the scientific, technological and engineering programme the project will work with a range of existing customers and new industrial partners to identify specific applications of this emerging additive manufacturing capability.
This project is an Engineering Doctorate – you will be based at the sponsor premises in Aldershot Hampshire for around 80% of the programme time, returning to the University for meetings and lectures. The project will commence on the 1st October 2019 and will be supervised by Dr Mark Whiting here at Surrey https://www.surrey.ac.uk/people/mark-j-whiting
Entry requirements: The Centre requires a minimum of a First or Upper Second. A Master’s degree is also acceptable with a minimum of a merit although a Distinction is preferred. Please note that the funding partner, the EPSRC has residency criteria – all applications are assessed on an individual basis. The requirements are set out here https://epsrc.ukri.org/skills/students/help/eligibility/
How to apply: Please let the Centre Manager, Noelle Hartley, have an expression of interest by email to [email protected] The Centre will then liaise directly with you for next steps.
Full stipend is paid at around £20,000 pa. All fees liability is met separately. See our programme website for programme information View Website International students are not eligible for this project.