PhD Study : Additive Manufacture via Cold Metal Transfer

Apply and key information  

Summary

The UK National Strategy for Additive Manufacturing / 3D printing (AM-3DP) highlights the UK’s opportunity in the rapidly expanding AM market. The global market of AM products and services in 2017 was estimated to be £6bn of which the UK share is in the region of 5%.

These markets are reported to be growing currently at a rate of 30% annually and with strong growth in the UK market the UK share has been forecasted to be $1bn in 2020 rising to £5.6bn in 2025.(Smith and Maier, 2017).

The advance of Additive manufacture has widened the opportunities to use metallic wire feed stock materials to manufacture complex architectures that are unsuitable for traditional manufacturing techniques. Manufacturing is the conversion of material input into goods and the efficiency of this conversion process is driven in part by the selection of materials a key determinant of the environmental impact associated with manufacturing (Gutowski et al., 2009).

Additive manufacturing techniques offers the potential to reduce the input parameters into a manufacturing process in a number of ways , including:

  • Reduced waste
  • Geometry optimisation (hence lower weight and less material)
  • Secondary effects – such as lower transportation costs , lower inventory and replacement parts availability
  • Lower overall energy usage and cost
  • Customised and tailored properties (Chen et al., 2015).

Huang et al., 2013 have stated “AM is expected to become a key manufacturing technology in the sustainable society of the future”

Current research in AM conducted at Ulster (Magee) is examining the control parameters for the deposition of metal via Cold Metal Transfer (CMT) and robotic control, this follows the Wire Arc Additive Manufacture (WAAM) track. The research examines the process parameters to achieve high resolution and homogenous depositions while having a lay down rate well in excess of the more expensive and labour intensive Powder Bed Fusion techniques.

The project proposed here will examine a critical aspect of the additive manufacturing supply chain, that is, the morphology and condition of the feedstock for AM via CMT.

The effect of the cyclical heat cycle associated with the WAAM deposition process can impart properties into a deposition that may be unfavourable.

The ability to control or mitigate against these properties by way of bespoke feedstock composition could reduce the amount of post processing requirement for many of the product that WAAM will be suitable for e.g. Wing spars, Floor beams, ribs etc Utilising the current WAAM infrastructure ( Robotic Arm and CNC Table) at Magee, the project will in the first instance use commercially available feed wire and study the effects on the micro and macro structure of the deposited material.

Studies to be completed will include but are not limited to :

  • Comparative assessment of wire feedstock by experimentation
  • Processing considerations - and development of process control strategies
  • Deposition strategy and modelling of effects of geometry of deposition pathways
  • Analysis of deposition including - chemical composition and mechanical properties

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.

Funding and eligibility

The University offers the following levels of support:

Vice Chancellors Research Studentship (VCRS)

The following scholarship options are available to applicants worldwide:

  • Full Award: (full-time tuition fees + £19,000 (tbc))
  • Part Award: (full-time tuition fees + £9,500)
  • Fees Only Award: (full-time tuition fees)

These scholarships will cover full-time PhD tuition fees for three years (subject to satisfactory academic performance) and will provide a £900 per annum research training support grant (RTSG) to help support the PhD researcher.

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.

Please note: you will automatically be entered into the competition for the Full Award, unless you state otherwise in your application.

Department for the Economy (DFE)

The scholarship will cover tuition fees at the Home rate and a maintenance allowance of £19,000 (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

The Doctoral College at Ulster University

Key dates

Submission deadline
Monday 18 February 2019
12:00AM

Interview Date
March 2019

Preferred student start date
September 2019

Applying

Apply Online  

Other supervisors