PhD Studentship: Wire and arc additive manufacture for maritime construction â assessment of structural integrity and degradation in service environments (858517BX)

Project Reference: EngSci-NCATS-296

This project aims to reveal the differences between conventional materials and their corresponding AM equivalents in terms of mechanical properties, corrosion performances and structural integrity for large-scale maritime applications. With the potential of manufacture large metallic components, the wire and arc additive manufacture (WAAM) technique will be explored. Basically a micro-welding process, it combines an electric arc as heat source and wire as feedstock by incremental layer-by-layer material consolidation. The project will examine ferrous materials such as C-Mn carbon steel and 316L stainless steel, identify their specific service/application environment on maritime structures, including loading levels and expected service life. WAAM specimens will be manufactured according to the application-specific requirements and the Guidance Notes for AM metallic parts published by Lloyd’s Register and TWI. Subsequently, the project will develop experimental assessment protocols to systematically examine the WAAM microstructures, their associated mechanical and corrosion properties. The effects of microstructure change and residual stresses induced by WAAM will be measured to help understand the degradation/corrosion mechanisms and quantify the corrosion resistance when exposed to harsh maritime environment.

The experimentally obtained mechanical and corrosion performance will be utilised as input and boundary conditions for large-scale numerical simulations (finite element analysis) of potential WAAM structures, in order to predict the long-term material deterioration and structural integrity/ultimate strength under actual loading conditions. By comparing to the conventional metallic components, the proposed research will advance the state of art of WAAM materials; increase the technology readiness for large-scale maritime applications and help industry to achieve the qualification of this technique in a safe and reliable manner.

This project aims to understand the differences between conventional materials and their corresponding WAAM equivalents in terms of material degradation and mechanical/structural integrity for large-scale components in maritime service environments. It will be achieved by following objectives:
1. Down selection of test materials after reviewing and identifying optional WAAM process and post-processing specifications;
2. Characterise the selected WAAM metallic materials;
3. Establish repeatable mechanical and electrochemical measurements;
4. Comparison with conventional material properties;
5. Predict long-term corrosion and structural integrity/performance in service.

Research outcomes will be utilised to establish possible feedback to WAAM process and post-processing specifications.
Entry requirements: The studentship is available to candidates with the equivalent of a first class degree in a related science or engineering discipline.

If you wish to discuss any details of the project informally, please contact Dr Julian Wharton, National Centre for Advanced Tribology at Southampton (NCATS) research group, Email: j.a.wharton@soton.ac.uk, Tel: +44 (0) 2380 59 2890.

To apply, please use the following website: http://www.southampton.ac.uk/engineering/postgraduate/research_degrees/apply.page

Closing Date: 03 Apr 2018
Post Type: PhD Studentship (Funded)