High Deposition Rate and High-Fidelity Process For Repair and Remanufacturing Applications PhD

Cranfield University is offering an exciting opportunity for a fully-funded PhD studentship in the field of repair and remanufacturing for engineering components. This project aims to develop a high deposition rate and high fidelity wire-based process for repair and remanufacturing applications based on hybrid laser and arc, which enables a steady deposition process with independent control of thermal cycle and bead shape, ensuring the achievement of desired properties of the repaired parts.

Remanufacturing is an industrial process aimed at restoring used or worn products to a ‘like-new’ or ‘better-than-new’ condition through comprehensive steps, including disassembly, cleaning, repair, and reassembly of components. This process often involves upgrading or replacing specific parts to enhance performance and extend the product’s lifecycle. Remanufacturing is commonly applied in industries such as automotive, aerospace, and heavy machinery, where it not only conserves resources and reduces waste but also provides cost-effective alternatives to new products. Currently there is more emphasis on repairing and reusing components in particular for high-value assets, which plays an important role in the concept of a circular economy.

State-of-the-art technologies such as submerged arc welding (SAW) and gas metal arc welding (GMAW) need high energy input, resulting in high dilution and large heat-affected zone (HAZ), causing metallurgical defects in the material. While laser directed energy deposition (L-DED), and plasma transferred arc (PTA) provide lower deposition rate, hence higher cost. Powder-based cladding processes are more expensive than wire counterparts, due to higher material cost and its lower utilisation.

This project will develop a high deposition rate and high fidelity wire-based process for repair and remanufacturing applications, which enables a steady deposition process from initiation to termination with independent control of thermal cycle and bead shape, ensuring the achievement of desired properties of the repaired parts as compared to those of the virgin parts. The aim of the project is to develop an advanced cladding process with high deposition rate and high fidelity based on hybrid laser and arc for repair and remanufacturing applications. The specific objectives are:

• To identify the most suitable process (laser, PTA, or PTA-laser hybrid) for repair and remanufacturing.
• To achieve independent control over thermal cycle and bead shape, ensuring high geometrical accuracy, low dilution and optimal thermal conditions.
• To integrate advanced process monitoring techniques (optical sensors and vision cameras) into the process.
• To assess the extent of damage to the virgin material by the repair process.
• To evaluate the process efficiency and cost-effectiveness of the process.
• To develop a repair procedure for management of key output variables that control final properties in the material.

You will be based at the Welding and Additive Manufacturing Centre at Cranfield University, renowned for its pioneering research in large-scale metal additive manufacturing and advanced welding techniques. Additionally, the student will have opportunities to travel across Europe to collaborate with our EU partners during the project.

Entry requirements

You should have a first-class or 2:1 UK degree (or equivalent) in a related discipline such as mechanical engineering, materials science, or welding engineering. Experience with wire-directed energy deposition (DED), welding, or robotics, as well as a strong understanding of material behaviour, sensors, and process monitoring, would be highly desirable.

You should be self-motivated, have good communication skills, and be able to collaborate effectively with academic and industry stakeholders.

International students should also meet the English language entry requirement of Cranfield University.

Diversity and Inclusion at Cranfield

At Cranfield, we value our diverse staff and student community and maintain a culture where everyone can work and study together harmoniously with dignity and respect. This is reflected in our University values of ambition, impact, respect and community. We welcome students and staff from all backgrounds from over 100 countries and support our staff and students to realise their full potential, from academic achievement to mental and physical wellbeing.

We are committed to progressing the diversity and inclusion agenda, for example; gender diversity in Science, Technology, Engineering and Mathematics (STEM) through our Athena SWAN Bronze award and action plan, we are members of the Women’s Engineering Society (WES) and Working Families, and sponsors of International Women in Engineering Day. We are also Disability Confident Level 1 Employers and members of the Business Disability Forum.

Funding

The studentship is fully funded for 3 years, covering full tuition fees and providing a tax-free bursary of £20,000 per annum to cover living costs.

Sponsored by Horizon Europe programme.

This opportunity is open to UK and international students.

Cranfield Doctoral Network

Research students at Cranfield benefit from being part of a dynamic, focused and professional study environment and all become valued members of the Cranfield Doctoral Network. This network brings together both research students and staff, providing a platform for our researchers to share ideas and collaborate in a multi-disciplinary environment. It aims to encourage an effective and vibrant research culture, founded upon the diversity of activities and knowledge. A tailored programme of seminars and events, alongside our Doctoral Researchers Core Development programme (transferable skills training), provide those studying a research degree with a wealth of social and networking opportunities.

How to apply

For further information please contact: 

 Name: Dr Wojciech Suder or Dr Chong Wang

Email: w.j.suder@cranfield.ac.uk or chong.wang1@cranfield.ac.uk

If you are eligible to apply for this studentship, please complete the online application form.