Structural Integrity and Qualification of 316L Austenitic Stainless Steel by Optimisation of Additive Manufacturing Process Parameters

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The structural integrity of safety-critical engineering components depends on the accurate prediction of the fatigue cracking and remaining life. Additive manufactured (AM) components show anisotropic mechanical properties, high residual stresses and strong crystallographic texture. These issues affect the structural integrity of as-build AM components and are a major hindrance in the qualification of industrial components. The demonstration of safe performance and structural integrity of AM safety critical components demands accurate prediction of cracking behaviour in fatigue loading.

Current fatigue crack propagation models have been developed for engineering alloys where the effects of residual stresses, crystallographic texture and, in particular, anisotropic properties are not considered. The project will develop a comprehensive model of structural integrity of safety critical Selective Laser Melted (SLM) austenitic stainless steel AISI 316L alloy. The model will be applicable to diverse complex loading conditions and will help in reducing the experimental testing. The modelling algorithms such as Finite Element Analysis with residual stresses, crystallographic texture and anisotropic properties for investigation of the fatigue cracking behaviour of the alloy will be a significant value addition into existing product design tools. This will enable design engineers to better predict the deformation behaviour of materials during service life of components.

About the Host Centre:
Our research in the Centre of Manufacturing and Materials Engineering (MME) builds upon our historic research at Coventry, and adds new research teams through investment and growth. It integrates seamlessly with the Institute for Advanced Manufacturing and Engineering, our flagship collaboration with Unipart Manufacturing.

This area of research will take a holistic approach to fabrication and manufacturing, focusing on the three strands of Materials, Processes and Products; and underpinned by our expertise in Materials Engineering and Advanced Experimentation and Modelling Approaches.

NSIRC is a state-of-the-art postgraduate engineering facility established and managed by structural integrity specialist TWI, working closely with top UK and International Universities and a number of leading industrial partners. NSIRC aims to deliver cutting edge research and highly qualified personnel to its key industrial partners.

Candidate Specification:
Successful applicants will have:

• A good first degree in Material Engineering, Physics or Mechanical Engineering with a minimum 60% mark in the Project element or equivalent with a minimum 60% overall module average, or

• A Masters Degree in a relevant subject area will be considered as an equivalent. The Masters must have been attained with overall marks at merit level (60%). In addition, the dissertation or equivalent element in the Masters must also have been attained with a mark at merit level (60%).

• The potential to engage in innovative research and to complete the PhD within a prescribed period of study

• Language proficiency (IELTS overall minimum score of 7.0 with a minimum of 6.5 in each component).

Additional Items for Candidate Specification:
Candidates with suitable work experience and capacity in numerical modelling, finite element modelling, and laboratory based experimental testing are particularly welcome to apply.

Duration of Study:
Full-Time - three years six months fixed term

Application Procedure:
Application information can be found in our how to apply section. Before completing the application please contact Dr. Muhammad Kashif Khan ([Email Address Removed]) (and cc in [Email Address Removed]) for an initial informal discussion about the opportunity.

Application Deadline:
This opportunity will only remain open until a suitable candidate is identified- early application is therefore advised. Standard University research application closing dates apply http://www.coventry.ac.uk/research/research-students/application-dates/