Development of manufacturing processes for large scale CMC components

Please note that this is an EngD project - and that you will be based with the sponsor at the site near Bristol. In recognition of this we pay an enhanced stipend of around £20,000.

The NCC is directly involved in a research programme co-funded by InnovateUK aiming at developing a processing methodology for the manufacture of series of substantial jet engine components in Ceramic Matrix Composite (CMC) materials. The Centre is therefore expanding their established knowledge, skills and manufacturing capabilities to enable delivering the necessary process development and eventually the demonstrators into the programme.

This project is part of such programme and will focus primarily on the identification of the manufacturing constraint for the production of the selected components out of CMC OxOx materials. The EngD candidate is expected therefore to be working closely with the NCC team delivering to InnovateUK, as the project deliverables, timeline and work structure will be aligned to the requirements of the funding body. As a critical part of the research team, the EngD candidate will be required to interact closely with the sponsoring company (a leading supplier to the aerospace sector).

The relatively large scale of some of the components being investigated will inevitably pose challenges to the current knowledge, and it is expected that innovative systems, processes, tooling and potentially equipment will have to be identified during the course of the research work. The student’s activities will be a mix of both practical and theoretical, with significant interaction expected with material and equipment suppliers. Potentially, if the NCC decides to invest heavily in this sector from a capability perspective, the student will be involved in the specification and procurement of the relevant pieces of equipment.

Within the first 12 months, the EngD candidate is expected to:

• Carry out a comprehensive critical literature review on the relevant topics;
• Acquire familiarity with CMC materials, understanding their fundamentals, potential and limitations;
• Define fully the project scope and objectives;
• Provide detailed project schedule and planning for the whole project;
• Identify the critical high-level parameters to investigate and define a D.O.E. to assess their effects on the part quality.