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Experimental, Numerical and Computational investigation of the feasibility of an integrated hybrid machining and TIG based surface alloying process

About This PhD Project

Project Description


The use of thermal spray coatings is a multi- billion pounds industry, for improving the life span, reliability and durability of engineering components in industries that span automotive, aerospace, marine and sea-going vessel engine components, oil and gas, power generation turbines. Manufacturing/ process industries and earth moving equipment. The cost of replacement of component parts, exposed to extreme environments such as aggressive wear, corrosion and degradation is a major economic factor in industrialised countries around the world. This has led to the development of companies that produce highly durable coatings to reduce the economic cost. The current major methods of coatings such processes is through Plasma Spraying, thermal spraying, Laser Alloying and a lot of these techniques use both Manual and Robotic techniques to deliver the surface coating process.

The major players in this industry in include ABB Robotics, Siemens and Curtis-Wright in the USA. As with many industrial sectors there is always a need to cut the down operating costs, reduce material wastage, improve product quality and comply with environmental protection requirements. One of the major costs involved in the engineering surface coating industries especially, when a protective coating has to be put on machined/manufactured product immediately after production is that it is usually a two stage process involving costs. Manufacturing companies tend to be separate from engineering coating companies. The manufactured products require transportation to another site, involving tool set-up and several additional costs.

This process has led to the formation of innovative companies that have operated as one stop shows for both manufacturing and surface coatings that include DCL Surface engineering, Australia, Skandinavisk AB and a number of others around the world. Most of these companies are actually semi-integrated and they are mainly based the thermal spraying deposition method. This method involves a substantial amount of materials wastage and other engineering issues such as conformity and the control of surface roughness of the coatings.

How to Apply

Applicants will normally hold a UK honours degree 2:1 (or equivalent); or a Masters degree in a subject relevant to the research project. Equivalent professional qualifications and any appropriate research experience may be considered. A minimum English language level of IELTS score of 6.5 (or equivalent) with no element below 6.0 is required. Some research disciplines may require higher levels.

Candidates are encouraged to contact the research supervisors for the project before applying. Applicants should complete the online GCU Research Application Form, stating the Project Title and Reference Number (listed above).

Please also attach to the online application, copies of academic qualifications (including IELTS if required), 2 references and any other relevant documentation.

Please send any enquiries regarding your application to: Applicants shortlisted for the PhD project will be contacted for an interview.

For more information on How to apply and the online application form please go to

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