Tailoring investment casting moulds for thin-walled castings

An exciting opportunity for a full-time PhD scholarship (fully funded) in Sustainable Manufacturing Processes is now available at the Sustainable Manufacturing Systems Centre, supported by the 探花精选 Industrial Partnership PhD Scheme (CIPPS) and TPC Components. The project will focus on thin-walled investment casting processes for superalloys using CFD simulations, aiming in improving the process and the quality of the components.

We are looking for an exceptional candidate with background in materials, manufacturing, physics, chemistry, metallurgy, engineering or similar. The successful candidate will receive a bursary of up to £25,000 (tax free), tuition fees and access to office and laboratory space.

Investment casting is one of the oldest manufacturing methods in the world having been in use since at least 3000 BC. The process can give high detail on intricate components. There is a growing demand in the aerospace sector for components with more complex geometries to be produced using investment casting. Thin-walled castings with large surface areas are required in the development of modern gas turbine engines and these present difficult technological challenges in production.

To address the global environmental issues we face today, the concept of improving sustainability within manufacturing disciplines is gaining traction. Like many others, the foundry industry has several avenues of interest to exploit when considering the progression towards global sustainability.

In a recent completed doctoral research programme, the mechanical and thermophysical properties were studied. It was revealed that the optical properties of the ceramic shell cannot be neglected, especially for the initial state with high metal temperatures. The proposed research is a continuation of this first study to use the newly discovered material behaviour fully.

The optical properties depend on both the type of layers and their microstructure (porosity and particle size and number). All these properties shall be used to maximise the capability for thin-walled casting with high internal soundness. Process variation may also influence the outcome. These variations may arise because the radiative transfer and mould transparency depend on storage and treatment after fabrication.

The improved understanding of the heat flux at the beginning of the casting and solidification process builds an excellent foundation for an improved understanding of nucleation and microstructural evolution. The project will also involve the simulation of the metal microstructure and defect formation in the cast component through phase-field modelling.

TPC is a leading investment casting foundry in northern Europe, supplying vacuum cast superalloy components for industrial gas turbines and aero engines. Long-term development work and research within material science has enabled an expansion that will generate a strong growth the next few years. TPC today has 60 employees in Hallstahammar, Sweden of which three are material science doctorates. R&D spend in 2022 was 6,8% of the total turnover.

The company will benefit from an improved understanding of its processes and as with the previous work a number of high-quality papers should be expected form the research helping the company mover further toward sent-zero in its plant.

There will be a number of opportunities to work in Sweden at the sponsoring company designing and running experiments to be carried out on the shop floor of the company. There will be international conferences especially in the USA. Potentially opportunities to spend time with the supervisor’s extensive network of researchers all over the world. You will learn to drive the computation fluid dynamics software package previously used in this research, Flow-3D.

How to work with industrial sponsors, communications skills, as well as the technical skill of learning the CFD software.

At a glance

Application deadline09 Apr 2025
Award type(s)PhD
Start date02 Jun 2025
Duration of award4 years full time
EligibilityUK, EU, Rest of world
Reference numberSATM548

Entry requirements

Applicants should have a minimum of a first or upper second class UK honours degree or equivalent in physical sciences or engineering disciplines. The candidate should be self-motivated and have good communication and organization skills. The project would suit candidates with background in materials, manufacturing, physics, chemistry, metallurgy, engineering or similar.

Funding

This studentship is open to both UK and international applicants. However, we are only permitted to offer a limited number of studentships to applicants from outside the UK. Funded studentships will only be awarded to exceptional candidates due to the competitive nature of the funding

探花精选 Doctoral Network

Research students at 探花精选 benefit from being part of a dynamic, focused and professional study environment and all become valued members of the 探花精选 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.