PhD Study : In-situ monitoring of metal deposition for robotic Wire Arc Additive Manufacturing process

Summary

A group at Ulster University are strongly engaged in developing computer models of metal additive manufacturing processes [1]. These models have been applied to industrial settings and are useful in solving practical problems such as the avoidance of defect formation in Powder Bed Fusion processes [2]. A new area for development within this group is in Wire Arc Additive Manufacturing (WAAM) processes for metal alloys. The group has on-site access to state-of-the-art robotic layer deposition technology (metal inert gas and cold metal transfer welding robots) [3], on-site metallurgical facilities, and in-situ monitoring equipment using state-of-the-art High Dynamic Range (HDR) thermal imaging, melt pool monitoring cameras [4].

The in-situ real-time process monitoring technology installed on Robotic WAAM process can be used for arc behaviour analysis and material deposition phenomenon study. By understanding of the arc behaviour and material deposition phenomena, manufacturers can develop effective strategies to minimise surface roughness and residual stresses in the WAAM process. The monitoring technology will help to investigate the factors influencing arc stability. It will also give the real-time picture of the melt pool dynamics, which will be helpful in controlling heat input and deposition rate. The project aims to use the in-situ monitoring technology for investigating the material deposition strategy and develop advanced tool path techniques to ensure a higher quality deposition. It also focuses on the fine-tuning of the process parameters that can help in mitigating the generation of residual stresses or warping of the components.

This project would suit prospective candidates who are enthusiastic about metal additive manufacturing and who have an interest in exploring experimental methodologies for solving industrial problems. The successful candidate will gain significant knowledge and skills in using in-situ real-time process monitoring technology and in materials research. This project should appeal to candidates from Engineering disciplines such as Mechanical, Manufacturing, or 3D printing/Additive manufacturing with desirable knowledge in robotics, process monitoring, or image analysis.

Essential criteria

Applicants should hold, or expect to obtain, a First or Upper Second Class Honours Degree in a subject relevant to the proposed area of study.

We may also consider applications from those who hold equivalent qualifications, for example, a Lower Second Class Honours Degree plus a Master’s Degree with Distinction.

In exceptional circumstances, the University may consider a portfolio of evidence from applicants who have appropriate professional experience which is equivalent to the learning outcomes of an Honours degree in lieu of academic qualifications.

• Sound understanding of subject area as evidenced by a comprehensive research proposal

Desirable Criteria

If the University receives a large number of applicants for the project, the following desirable criteria may be applied to shortlist applicants for interview.

• First Class Honours (1st) Degree
• Masters at 65%
• Work experience relevant to the proposed project
• Publications - peer-reviewed

Equal Opportunities

The University is an equal opportunities employer and welcomes applicants from all sections of the community, particularly from those with disabilities.

Appointment will be made on merit.

Funding and eligibility

The University offers the following levels of support:

Department for the Economy (DFE)

The scholarship will cover tuition fees at the Home rate and a maintenance allowance of £19,237 (tbc) per annum for three years (subject to satisfactory academic performance).

This scholarship also comes with £900 per annum for three years as a research training support grant (RTSG) allocation to help support the PhD researcher.

• Candidates with pre-settled or settled status under the EU Settlement Scheme, who also satisfy a three year residency requirement in the UK prior to the start of the course for which a Studentship is held MAY receive a Studentship covering fees and maintenance.
• Republic of Ireland (ROI) nationals who satisfy three years’ residency in the UK prior to the start of the course MAY receive a Studentship covering fees and maintenance (ROI nationals don’t need to have pre-settled or settled status under the EU Settlement Scheme to qualify).
• Other non-ROI EU applicants are ‘International’ are not eligible for this source of funding.
• Applicants who already hold a doctoral degree or who have been registered on a programme of research leading to the award of a doctoral degree on a full-time basis for more than one year (or part-time equivalent) are NOT eligible to apply for an award.

Due consideration should be given to financing your studies. Further information on cost of living