Multi-scale corrosion assessment of additively remanufactured metallic components

This PhD will investigate the corrosion behaviour of additively remanufactured stainless steel in collaboration with Sulzer. ‘Remanufacturing’ utilises additive manufacturing techniques to rework damaged or worn components, restoring their function with notable cost, lead-time and environmental benefits to industry. Despite the unique benefits of remanufacturing, there is a requirement to understand the aqueous corrosion behaviour of additively remanufactured components to enable wider adoption of the technique. This interdisciplinary PhD project will develop the necessary corrosion understanding of remanufactured stainless steel in aqueous CO2-containing environments, typical of geothermal energy and carbon capture infrastructure.

Additive manufacturing is achieving rapid adoption across manufacturing industries, offering significant advantages over traditional manufacturing through the provision of new design freedoms, material-usage efficiencies, and bespoke production. However, corrosion is a major challenge that can cause rapid degradation of materials as a result of interaction with an aqueous environment. Corrosion behaviour of traditional manufactured materials has been widely studied, but understanding has yet to be established for additively manufactured materials. Developing this understanding is essential, particularly in demanding aqueous CO2-containing environments that can lead to high rates of corrosion. Of particular interest in this project will be the interface between the original traditional manufactured component and the additively remanufactured repair zone, where galvanic and localised corrosion may be initiated.  

We are looking for an enthusiastic graduate with an interest in materials chemistry, engineering materials and/or material science to join this project based between the Schools of Mechanical Engineering and Chemical and Process Engineering. In partnership with Sulzer, additive remanufacturing will be evaluated for application in renewable energy and carbon capture infrastructure, utilising specialised electrochemical techniques and state-of-the-art electron microscopy facilities to evaluate corrosion behaviour.  

Company spotlight

Sulzer Ltd is internationally renowned leader in flow equipment technologies; particularly high-performance pumps used in shipping, energy generation, and transportation of fluids. Sulzer has a large-scale manufacturing and testing facility in Leeds. This studentship will hugely benefit from the direct support and mentoring from the research and production staff at Sulzer, complemented by access to equipment and materials to facilitate the research.