PhD Studentship: Effect of Additive Ceramic Core Material Formulation on Rheology and Particle Segregation During Build and Its Contribution to Shrinkage Anisotropy and Interlayer Strength

Do you want to work at the cutting edge of Aerospace manufacturing technology? Are you interested in Additive Manufacturing? Do you want to work as part of a cross-functional team making aircraft propulsion systems more efficient and sustainable for the future of air travel? Join our internationally unique collaboration between the University of Birmingham and Rolls-Royce at the High Temperature Research Centre (HTRC) located in Ansty Business Park.

The team comprises ~100 personnel including Rolls-Royce Design and Manufacturing Engineers, University of Birmingham Academics, Research Fellows, and Students. The facility boasts a world leading laboratory for advanced material and formulation characterisation as well as a process line that mirrors Rolls-Royce’s production investment casting capability. This enables us to deliver robust solutions across key areas: supporting experimental engine demonstrators, manufacturing technology development, and fundamental research that aids both future technology and domestic manufacturing improvements. Additionally, the facility houses a production-scale ceramic additive manufacturing line.

Applicants are invited to apply to undertake an PhD programme to address the “Effect of additive ceramic core material formulation on rheology and particle segregation during build and its contribution to shrinkage anisotropy and interlayer strength”. The successful candidate will work as part of a cross-functional team dedicated to developing future design concepts to create a step change in turbine component cooling performance.

Training will be provided in selecting methods and using laboratory equipment for material and process characterisation. You will be trained in the HTRC quality system for initiating and managing larger experiments, and in the manufacturing of investment castings through the Rolls-Royce casting academy.

You will evaluate how ceramic slurry formulation affects fine feature formation capability, shrinkage anisotropy and interlayer strength in the fired ceramic component, and therefore the ability to produce a dimensionally consistent ceramic part that remains stable during the casting process. You will develop and execute novel laboratory experiments to characterize physical processes such as particle settling, and liquid surface texture caused by surface tension effects. You will develop a mathematical model and perform numerical simulations to better understand the influence of the ceramic-system material properties & re-coater and component geometry on the recoated surface topology. You will explore the effects of factors such as particle size distribution, particle shape, solids loading, dispersants as well as process parameters such as shear-rate and temperature on the rheological characteristics and how these affect the fired ceramic dimensions and properties. You will optimize the ceramic-chemistry and binder-system characteristics to develop new formulations.

Drawing links between the formulation, microstructure, and processing of the existing additive manufacturing process at the HTRC, you will contribute to the scientific community by delivering conference and journal publications using non-IP sensitive model systems.

To apply please email your CV to a.cendrowicz@bham.ac.uk.

Funding Notes:

The successful applicant will get a tax-free bursary of £24,600. To be eligible, candidates must have at least a 2(1) in an Engineering or Scientific discipline or a 2(2) plus MSc. Tuition fees are covered for UK home students.

Due to the nature of work the HTRC conducts, and the protection of certain assets, candidates must willing to apply for and able to obtain BPSS clearance & be UK nationals or from non-ITAR sanctioned countries. Holders of US citizenship, residency permits, leave to stay, current or previous green card holders cannot be considered for the position.

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