Research Fellow in Disruptive Additive Manufacturing Microstructures via Beam-Shaping

LONDON’S GLOBAL UNIVERSITY

Job Description

Research Fellow in Disrupting Additive

Manufacturing Microstructures via beam-shaping

Department: Mechanical Engineering

Reports to

Prof. Peter D. Lee, UCL Mechanical Engineering.

Context

The has a of in situ and The postholder will work in the additive manufacturing (AM) portion of the Multi-Scale X-ray Imaging Laboratory gen.

(MXI-Lab) led by Profs. Lee and Leung. The group is based in the Research Complex at Harwell (RCaH, www.rc-harwell.ac.uk/), Rutherford Appleton Laboratory (RAL), in Oxfordshire. The group’s research projects are will be by a team of strongly linked to the large facilities, including Diamond Light Source (DLS), the European Synchrotron Radiation Facility (ESRF), the Advanced Photon Source (APS).

The project will involve carrying out fundamental studies to reveal, understand and quantify the fundamental hydrodynamic, solute transport and microstructure rig evolution mechanisms at work when applying external fields to the directed energy deposition process (DED), and altering the laser power distribution. You will develop these mechanisms to optimise AM microstructures, reducing defect formation (e.g. epitaxial growth and porosity), realising a pathway for industrial exploitation.

.

This involves ultra-fast in situ synchrotron and correlative optical or infrared (IR) imaging using custom-made in situ

AM machines, and adapting and improving these rigs.

be by the of The Department of Mechanical Engineering track of the . You will be The Department of Mechanical Engineering at the UCL is at and an internationally recognised centre of excellence for the fields of advanced materials, materials processing, and modelling. The Mechanical Engineering Department at

Grade 7

Location: The Research Complex at Harwell, Harwell, Oxfordshire

UCL began in 1847 with the appointment of a “Professor Mechanical Principles Engineering”, mechanical engineering chair in the country.

MXI-Lab developed range operando AM machines including the Blown Additive Manufacturing Process Replicator (BAMPR-2) which replicate industrial machines to enable probing of the physics of AM using correlative synchrotron X-ray, infrared (IR), optical and other imaging modalities. You supported post-doctoral researchers, PhD students and support staff developing and applying these unique machines both for synchrotron and laboratory source imaging to gain novel insights into materials and their processing. In situ experiments will be conducted at both Diamond Light Source and ESRF. You will lead the adaptation of an existing powder directed energy deposition in situ (working with a Design Engineer) to modify the energy distribution of the laser.

You will also apply ultrasonic fields to the melt pool to modify the solidification processes. You will then use ultra-fast synchrotron X-ray imaging to demonstrate how these process modifications transform AM solidification microstructures You will be based at the RCaH, Oxfordshire, and you will employed

Department Mechanical

Engineering at UCL. The position is for 18 months with the salary depending on qualifications, experience and research record candidate performing experiments facilities worldwide, interacting with a wide range of academics, industrial and large facility researchers.

▪

Main purpose of the job

• Your role will be to adapt the existing BAMPR-2 rig ▪ (working with a Design Engineer) to accommodate non-gaussian beam distributions. You will then use ultra-fast synchrotron X-ray imaging to demonstrate ▪ how this process modification can transform AM solidification microstructures, coupled with ultrasound (US).

To mentor PhD students sited within the group and to work with visiting teams during experiments.

To help engender a team ethos within the group, integrating into the scientific life at Harwell Campus whilst engaging regularly with scientists at ESRF.

To assist other researchers (PG to Prof) in the group, and visitors.

• The overall goal of the project is to use ultrasound and non-gaussian energy distributions to modify pool shape, free surface behaviour, solute distribution, and local thermal gradients to improve the microstructure and reduce defects.
• You will also take responsibility for organising and coordinating the team of researchers in MXI-lab utilising BAMPR-II, focused on the DED technique.

Duties and responsibilities

• To lead the day to day project activities.
• To adapt the existing in situ rigs to accommodate a non-gaussian ring beam to enable the study of its influence using synchrotron and other imaging modalities.
• To use the existing experimental capability to apply ultrasound to the DED process, and to characterise its impact.
• To plan and conduct laboratory & synchrotron X-ray imaging using the equipment above to test scientific hypotheses, helping write beamtime proposals.
• To lead the MXI-lab team focused on DED, helping coordinate other researchers to optimise the production of high quality data and research.
• To analyse the big data produced, implementing data segmentation strategies, and ideally developing new image quantification algorithms using machine learning.
• To interpret the images/quantification from a physical metallurgical and manufacturing perspective.
• To maintain accurate, comprehensive and secure records of research data.
• To write technical reports for the sponsors and collaborators.
• To publish research in high-quality academic journals.
• To follow health and safety procedures to maintain a safe environment at work and prepare safety risk assessments.

Person Specification

Criteria

Qualifications, experience and knowledge

PhD or equivalent experience in materials science, physics, mechanical/electrical or other appropriate engineering subject.

Experience in advanced powder processes, ideally additive manufacturing, and directed energy deposition An in-depth knowledge of imaging and image analysis, ideally applied to Xray radiography, tomography, diffraction and correlative imaging.

Knowledge of at least two of the following areas

• Experience in design & use of complex equipment, ideally for use on a synchrotron.
• Experience of X-ray imaging in real or reciprocal space.
• Experience of conducting and analysing experiments using a synchrotron or neutron source.

Knowledge of physical metallurgy.

Knowledge of ultrasonic fluid dynamics and their application to DED.

An in-depth knowledge of at least one of the microstructural characterisation techniques applied to powder manufactured components.

Experience in programming and/or algorithm development Experience in writing beamline proposals

Skills and abilities

An excellent, stage-appropriate publication record in a relevant field.

Outstanding communication skills in English.

Experience in project management and handling multi-partner/site projects, ideally with industry.

Knowledge of safe working practices in laboratories.

Demonstrated ability to work independently and as part of a team, successfully completing complex research programmes, developing original research.

Demonstrated ability to lead complex, multi-disciplinary technical teams Ability to multi-task and prioritise your workload, meeting deadlines.

Powder and laser safety

Personal attributes

Eager to learn new practices and techniques Able to work collaboratively in a multidisciplinary team Essential or Assessment method Desirable (Application/Interview)

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