PhD Studentship - PhD in Control and monitoring of laser DED technology for coatings, repair and additive manufacturing (with Brunel and TWI)

Advanced manufacturing technologies such as additive manufacturing (AM) and surface engineering is used across industry for making end use parts. Laser technology such as laser beam directed energy deposition is a technology that can be applicable to coatings, repair and AM. However, uncertainty still exists around part to part consistency and repeatability, which is limiting greater adoption. A fundamental solution to help address this problem is the need for simple, yet agile, monitoring and control systems augmented by artificial intelligence.

Project Outline

This PhD will enable the successful candidate to develop/focus on:

Directed energy deposition (DED) with laser beam, an AM technique that is expected to see accelerated growth in industry in next 1-2 years.
Fundamental understanding and hands on experience of using state of the art DED equipment, including the novel extreme high-speed laser application process (EHLA).
Work within a team of highly talented and experienced engineers to help document DED parameters and characteristics that govern part quality.
Identify and install monitoring systems and develop control techniques and methodologies to improve part to part consistency.
Explore the use of digital analysis systems and AI approaches for closed loop control.
Work with industry to validate the methods on real part manufacturing.

Key words

Additive manufacturing; lasers; EHLA; coatings; repair; monitoring; control; AI;

TWI’s Sheffield facility is staffed with experts focused on research and industrialisation in additive manufacturing and houses UK leading DED and EHLA equipment for applications in additive manufacture, coatings and component repair. For the duration of your PhD you will be based at TWI in Sheffield.

NSIRC is a state-of-the-art postgraduate engineering facility established and managed by structural integrity specialist TWI, working closely with lead academic partner Brunel University, the universities of Cambridge, Manchester, Loughborough, Birmingham, Leicester and a number of leading industrial partners. NSIRC aims to deliver cutting edge research and highly qualified personnel to its key industrial partners.

Eligibility

Candidates should have a relevant degree at 2.1 minimum or an equivalent overseas degree in an appropriate engineering or science-based discipline. Overseas applicants should also submit IELTS results (minimum 6.5) if applicable. A degree in mechanical Engineering or materials science and related fields. An interest in computer science and artificial intelligence would also be desirable but not necessary. The successful candidate also needs to demonstrate enthusiasm to integrate and become part of the team at TWI and have the confidence to be taught to safely operate additive manufacturing equipment. Hence, a clear aptitude to develop and undertake research through practical trials and fundamental exploration is anticipated.

Funding Notes

This project is funded by Brunel University, London and TWI. The funding covers the cost of tuition fees and a standard tax-free stipend for three years.

How to apply

Please contact either emma.smith@brunel.ac.uk and hannah.stedman@twi.co.uk

Meet the Supervisor(s)

Qingping Yang - Dr QingPing Yang is currently the Group Leader for Brunel Quality Engineering and Smart Technology (QUEST) Research Group and Robotics and Automation Research Group. Dr Yang joined the Brunel Centre for Manufacturing Metrology (BCMM) in 1988 with a visiting scholarship awarded by the AVIC, after his graduation in Instrumentation and Measurement Technology from Chengdu Aeronautical Polytechnic in 1983 and subsequent 4 years’ research experiences at an Aircraft Structure Research Institute (AVIC, Xi’an) and admission to an MSc Programme in Robot Control and Intelligent Control at Northwestern Polytechnical University. In 1989, he was awarded an ORS Award and a PhD Studentship from British Technology Group to develop a patented smart 3D high precision probe system for CMMs, and he received his PhD degree in October 1992. Since then he has been working as a Research Fellow, Lecturer/Senior Lecturer/Reader (Associate Professor) at Brunel University London. He has actively participated in 15 (11 as Principal Investigator) research projects funded by the UK government, EU and industrial companies, with a total funding of about £2.5 million as Principal Investigator and £888K as Co-Investigator. Through more than 30 years dedicated research, he has developed a unique and coherent research field broadly integrating three research areas of sensor/measurement systems, quality engineering and smart technologies (including AI and robotics) with rigorous theoretical foundation, addressing the core science and technology underpinning these areas. He has published more than 110 journal/conference papers, 5 book chapters and 3 patents (one patent successfully assigned for commercial exploitation in 2004) in these areas. He has supervised (as the 1st supervisor) 20 PhD and 3 MPhil students with successful completion as well as 9 visiting academic staff / PhD students, and he is currently supervising one postdoctoral Research Fellow and 8 PhD students. Dr Yang has received numerous prizes and awards for outstanding academic and work performance in the past (including three performance bonuses in Brunel University). He has been a member of IEEE and IET. He was profiled in the 15th edition of Marquis Who’s Who in the World (1998) and the 5th edition of Marquis Who’s Who in Science and Engineering (2000).