Applications are invited for a three-year PhD scholarship within the
ARC Centre of Excellence for Design in Light Metals at Monash
University, supported by The European Space Agency and Rosebank
Engineering, on a project entitled 'Designer Microstructures through Cold Spray Powder Deposition'.
The Project
The manufacturing sector in general is currently focussing on increased efficiency, whether it be in the area of reduced emissions, lower scrap, less processing steps or shorter turnaround times.
In the aerospace environment, the buy-to-fly ratio is particularly important, and it is common for structural components in Aluminium or Titanium to have buy-to-fly ratios of 20:1 or even 40:1. Conventional alloy processing attempts to firstly achieve homogeneous alloy components and then to use thermal treatments to deliver an acceptable distribution of phases. This is not only inefficient but also restricts the range of resultant microstructures and therefore mechanical properties that are achievable.
A Metal Powder Report article in 2006 stated that Pratt and Whitney had estimated that the buy-to-fly ratio for some aerospace components could be reduced by 41% if a direct manufacturing process such as Cold Gas Dynamic Spraying (CGDS, commonly referred to as Cold Spray) could be utilised [[i]]. The process is carried out entirely in the solid state and it is possible to tailor microstructures that cannot be achieved by the conventional molten processing routes for specific combinations of properties. By clever manipulation of the structures, it will be possible to develop materials with entirely novel property space.
So far, the cold spray technique has been successfully applied to the formation of novel surfaces on components for wear and corrosion resistance, and recently 3D architectures have been produced. The aim of this project is to revolutionise the manufacture of alloy components by changing the material processing focus to the consolidation of advanced novel microstructures through cold spray and thus achieving superior mechanical properties.
The project is funded through an ARC Linkage grant, sponsored by the Department of Materials Engineering (Monash University), The European Space Agency(ESA) and Rosebank Engineering. The supervisors for the project are Professor Xinhua Wu (from Monash University) and Dr Wayne Voice (from ESA).
'Designer Microstructures through Cold Spray Powder Deposition' PhD Programme:
The overall objective is to construct components with 'designer' microstructures by cold spraying multiple powders of the required constituent phases and using HIPping to achieve the desired property envelope. New materials with high property specifications can thus be achieved through refinement of the alloy microstructure plus optimised distribution of alloy phases which in its extreme can become an alloy composite. The phases will be selected and their powder manufactured to a prescribed formula determined by modelling and experimentation to give a highly stable microstructure.
There are two aspects to the project:
- Fundamental scientific advances in the understanding of mixed powder flight behaviour with respect to chemistry, morphology, temperature and pressure.
- Design of novel microstructures. The process is carried out entirely in the solid state and it is possible to tailor microstructures that cannot be achieved by the conventional molten processing routes for specific combinations of properties. The design criteria will be formulated by modelling the behaviour of two phase structures, and validated by experiment. The effect of post-processing using HIP will also be explored.
The Opportunity
The scholarship provides an annual tax-free stipend of AUS $28,000.
Candidates must meet the eligibility criteria for PhD candidature at Monash University: http://www.mrgs.monash.edu.au/research/doctoral/chapter2a.html
Selection criteria
Candidates must be a citizen of either Australia, Canada or one of the ESA member states. A map showing the ESA member states can be found here: http://www.esa.int/About_Us/Welcome_to_ESA/New_Member_States
An outstanding candidate with sound metallurgy or materials science/engineering background is preferred and an interest in computer modelling of microstructures will be advantageous. Annual travel to Europe to attend project meetings is envisaged.
Enquiries
Ms Belinda Hofmeyr, belinda.hofmeyr@monash.edu
Dr Colleen Bettles, colleen.bettles@monash.edu, +61 3 9905 5247
For further information please visit: www.arclightmetals.org.au
Applications
Applications should include a cover letter specifying interests, qualifications and experience as it relates to the research project. Your curriculum vitae should include employment history, publications and the names and details of three referees. Please also attach a copy of your academic transcripts.
deadline: 2013-01-31
