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Robotic Ultrasonic System for In-situ Residual Stress Measurement in Metal Additive Manufacturing


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  Ms A Cohen  No more applications being accepted  Funded PhD Project (European/UK Students Only)

About the Project

Industry Partner: NNIS (National Manufacturing Institute Scotland)

Overview: Residual Stress (RS) in engineering components yields unexpected and dangerous structural ‎failures, and thus represents a significant challenge to quality assurance in both welding and metal ‎Additive Manufacturing (AM) processes. As automation in welding and AM becomes increasingly ‎prevalent in the Industry 4.0 manufacturing paradigm, so the importance of quantifying RS will ‎grow. In this PhD project, a novel robotic ultrasonic approach to measuring such RS, in-situ, will be developed using the Phased Array Ultrasonic Testing (PAUT) system, to automate the deployment of the ‎measurement in manufacturing applications. For the first time, it will allow truly in-situ ‎measurements of RS to be undertaken at the elevated temperatures associated with welding and ‎metal AM manufacture. The ambition is to use this in-situ measurement system for safety-critical and Industry 4.0 applications, through 5G wireless integration of the robotic system, where the conventional manual and destructive methods of RS ‎measurement are not applicable for high throughput and automated production lines.‎


Key Objectives:

The aim of this PhD project is the development of an in-situ PAUT RS measurement system in the metal additive manufacturing process. The core research objectives are as follows:‎

1)    Study novel ultrasonic phased array transducers and data extraction to measure RS

2)    Automate the RS measurement process using robot deployment of the sensor arrays

3)    Enable high-temperature operation of the measurement so that true in-situ measurement can be made

4)    Study the feasibility of 5G wireless integration of RS measurement robotic and PAUT system with the manufacturing robot

Pre-requisite skills / skills to be learnt during the course of PhD:

1)    Robotics

2)    Non-Destructive Evaluation (NDE) with a focus on the ultrasonic method and PAUT system

3)    Welding and Wire Arc Additive Manufacturing (WAAM)

4)    RS distribution and analysis in weld and WAAM

5)    Industry 4.0 and integration of robotic and PAUT systems using 5G technology

If you have an outline PhD Research Plan, please include, but not necessary at this time.

The following research and technical activities will be pursued to achieve the main aims of this PhD ‎work:‎

1)    A literature review covering residual stress measurement methods, NDE stress measurement approach, ultrasonic ‎method, PAUT, in-situ inspection/measurement, robotic NDT, and Industry 4.0 to ‎devise the methodology of ‎the research‎.

2)    Develop the PAUT and robotic RS measurement setup.

3)    RS measurement in WAAM components (ambient temperature).

4)    ‎RS measurement in WAAM components at the elevated temperature to study the effect of temperature on the RS distribution.

5)    Develop the in-situ RS measurement setup.

6)    Wireless 5G integration of the robots.

How to Apply:

Applications must be submitted through the University of Glasgow online application system with a cover letter, CV, two references and your transcript/degree certificate. When applying to this project, please insert the project name in to the “proposed thesis title” section and add “Prof Sandy Cochran” as the supervisor for the application.

Application deadline: 20th July 2022

For enquiries, please email [Email Address Removed]

Funding Notes

Funding is available to cover tuition fees for UK Home applicants and a stipend at the Research Council rate (£16,062 for 2022/23). To be eligible for a fully-funded Home studentship, you must be:
• a UK citizen (who has been resident in the UK/EEA/Switzerland/Gibraltar for the past three years)
• an EU citizen with ‘settled’ or ‘pre-settled’ status in the UK.
• an applicant with ‘indefinite leave to remain or enter’ the UK
We also accept international applicants that can self-fund or bring external funding to cover their tuition and living costs.
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