Real-Time Thermal modelling of additive manufacturing processes

Additive manufacturing processes can potentially create arbitrarily complex shapes which can be designed to support loads with a minimal mass. In order to ensure that parts are built with the best possible microstructure and residual stress throughout, it is necessary to control the temperature throughout the build. The aim of this project is to investigate the use of a GPU to rapidly solve the heat equation for an industrial-sized machine. A preliminary demonstration has already been coded using Matlab to demonstrate the speedup available for models with < 5 M elements; this project will focus on the automatic mesh coarsening, optimised algorithms, experimental validation, and understanding of microstructure.

Relevant skills include mathematics, computer science, materials science and/or physics. The EPSRC eligibility requirements are a relevant connection with the UK, usually established by residence; an upper second class honours degree, or a combination of qualifications and/or experience equivalent to that level. The project is expected to start in the Summer or early Autumn of 2016 through arrangement with the candidate.

The project is an EPSRC-supported ICASE award with Renishaw plc, and includes 3 months of work at one of their UK facilities with travel and subsistence costs covered. The supervisors will be Dr Mark Ward + Prof Moataz Attallah + Dr Nils Warnken (Birmingham) and Ceri Brown (Renishaw).