About the Project
Background
Selective laser melting (SLM) additive manufacturing is the process of making three dimensional (3D) components layer by layer using a high-energy laser beam to fuse the pre-deposited metal powder. The interest in SLM is growing within a number of industrial sectors (i.e., aerospace, medical, oil & gas, marine and defence etc.) due to its ability to produce complex netshape components directly from a CAD model allowing for increased design freedom without the constraints of traditional methods. Hence, this makes SLM a key method of a great potential in reducing manufacturing cost in comparison with conventional manufacturing techniques. There is currently a lack of knowledge regarding the influence of process variables on the integrity and properties of as-fabricated material. Hence, determining unknown relationships between material performance and process parameters remain a primarily important engineering task which currently represents barrier to extensive use of this technology, especially in safety-critical applications. Successful establishment of these relationships will provide a robust platform for the optimisation of SLM parameters to manufacture parts with target design properties.
Project Outline
The overall aim of this project is to develop an effective combination of experimental and computational methods to establish the relation between pre- and post-process parameters and their ultimate effects on the mechanical behaviour of SLMed nickel superalloys. Hence, tailored microstructure and residual stresses can be obtained by optimizing these process parameters so that laser melting of nickel superalloys can open up completely new possibilities and applications across many industries. To achieve our goal, multiaxial and multiscale residual stresses caused by SLM in samples will be measured and characterized as functions of process parameters. The impact of the grain morphology and crystal orientation on mechanical behaviour under loading conditions will be investigated with the help of Electron Backscatter Diffraction (EBSD) and a microstructure-based model.
About Industrial Sponsor
The Lloyd’s Register Foundation funds the advancement of engineer-related education and research and supports work that enhances safety of life at sea, on land and in the air, because life matters. Lloyd’s Register Foundation is partly funded by the profits of their trading arm Lloyd’s Register Group Limited, a global engineering, technical and business services organisation.
About NSIRC
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.
About the University
Founded in 1495, University of Aberdeen is the 5th oldest University in the UK has now over 14,000 full-time matriculated students with more than 3600 staff. The University’s research excellence has resulted in 5 Nobel prize winners. Inventions have been life changing globally with MRI scanning and insulin invention and the University continue innovation today with particularly strong energy, engineering, environment, health, law and business knowledge.
The School of Engineering is located on the King’s College Campus, which retains its medieval layout and village atmosphere, its fifteenth-century cathedral and its sixteenth-century University chapel. This heritage is fused with modern, state of the art facilities for research, learning and teaching, making it fit for purpose for the students of today. Over 82% of research in General Engineering is classified as either world leading or internationally excellent (REF 2014) and the School is constantly innovating. General Engineering is now the first in Scotland and in the top 10 in the UK (2017 Complete University Guide).
The Sir Duncan Rice Library at the University is one of the largest and best equipped in the UK, offering excellent learning resources to support studies. Designed by Danish architects, the £57 million building is an iconic architectural landmark of North East Scotland. The Library’s electronic resources include 29,000 journals and 500,000 books across all disciplines.
Candidate Requirements
Candidates should have a relevant degree at 2.1 minimum, or an equivalent overseas degree. This PhD studentship is open to UK home students or European students. Candidates with suitable work experience and strong capacity in numerical modelling and experimental skills are particularly welcome to apply. Non-native speakers of English who have not studied in an English speaking country will be required to submit IELTS results (minimum 6.5). The successful candidate will be registered for the PhD at the University of Aberdeen but is required to spend at least 80% of the time at NSIRC in Cambridge.
Funding Notes
This project is funded by Lloyds Register Foundation, TWI and academic partners. The studentship will provide successful Home/EU students with a stipend of £16k/year and will cover the cost of tuition fees.
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