The transport industry continuously seeks design and manufacturing solutions that enable lower fuel consumption and CO2 emissions. This includes hybrid structures involving different material classes (steel, titanium, aluminium and magnesium) and different material forms (rolled sheet, castings, and laminates). This project will focus on novel friction joining technologies for dissimilar material systems (friction stir, friction stir spot, and ultrasonic welding). It is funded by the Engineering and Physical Sciences Research
Council, EPSRC, and is in collaboration with Manchester University Materials Science
Centre.
The research in Cambridge will focus on development of process models for metal flow and heat flow in friction processing, using finite element analysis and computational fluid dynamics. Key challenges are:
– to develop and model a simple test rig to determine the material deformation response at the high temperatures and strain-rates characteristic of friction processing;
– to develop computationally efficient process models to optimise tool designs and welding conditions in dissimilar alloy joints;
– to develop a new process model for ultrasonic spot welding.
The Manchester group will be responsible for making the instrumented test welds on their in-house friction stir and ultrasonic welding machines, and for the detailed characterisation and modelling of microstructure evolution and interface reactions. Both groups will undertake mechanical testing of a range of joint geometries and material combinations.
The project will involve close collaboration with a current PhD student in Cambridge, and frequent visits to the project partners in the University of Manchester. Continuation to a PhD may be possible subject to available funding and satisfactory progress.
Background Required:
Applicants should have a 1st or 2.1 degree in Engineering, Manufacturing or Engineering Materials. Some previous experience of numerical modelling would be preferred.
Scholarship Application Deadline:1 March 2011
