PhD supervisor: Dr Iain Todd

Industrial supervisor: Dr Al Lambourne (Rolls-Royce)

Funding availability: Fully funded EPSRC studentship with Industrial CASE award stipend enhancement

Applications are invited from suitably qualified Materials Science/ Physics / Electrical Engineering / Mechanical Engineering / graduates for a PhD studentship within the Rolls-Royce University Technology Centre (UTC) at The University of Sheffield. The PhD will be interdisciplinary with supervision provided by the Department of Materials Science and Engineering with support from the Rolls-Royce University Technology Centre in Advanced Electrical Machines in the Department of Electrical & Electronic Engineering.

Project description:

This EPSRC and Rolls-Royce funded Studentship investigates internal finishing and polishing of complex structures for safety critical aero-engine components. The internal surfaces of some complex structural or functional components can exhibit relatively poor surface finish. This is particularly the case for components manufactured by additive layer manufacturing (ALM), the roughness could initiate fatigue cracks which compromise the reliability and life of a component.

On external component surfaces, finishing can be done via straightforward and well-established mechanical polishing methods. For internal surfaces, polishing is more challenging. This project will evaluate a new approach to internal polishing of complex structures which uses a novel polishing media that can be manipulated electromagnetically from the outside of the component. Time-varying magnetic fields will be used to manipulate the polishing media, providing consistent and predictable polishing to all internal surfaces of a component. This approach has significant potential as a new process for achieving highly polished internal structures of complex components with surface finish and fatigue properties comparable with conventionally processed material. 

At present, a reliable and adaptable internal surface finishing technology is one of the major technical hurdles restricting the widespread use of complex internal structures in aerospace applications. If successful this new technology will enable designers to fully realise the potential of ALM, allowing unparalleled geometric freedom for a design and manufacture of complex components with hitherto impossible levels of detail and functional integration.

Project objectives include:

• Development & characterisation of polishing media
• Electromagnetic modelling of the component and the polishing media interaction
• Technology validation and demonstration via a custom test rig

The project can be tailored to include: 

• Training within Rolls-Royce to enable the understanding of the wider technical issues related to the project, and develop partnerships with industrial counterparts. 
• Joint academic and industrial supervision to develop academic and industrial skills, broadening future career opportunities. 
• The opportunity to participate in teaching or lab supervision. 

The University of Sheffield have excellent facilities in electromagnetic modelling, electrical machine design, additive layer manufacturing, materials testing and materials characterisation to support this research project. Students will benefit from the strategic partnerships with industry and collaborations with world-class specialists in electrical and materials technologies.

Informal enquiries may be addressed to:

Professor Geraint Jewell: g.jewell<στο>sheffield.ac.uk

Dr Iain Todd: i.todd<στο>sheffield.ac.uk

Dr Al Lambourne: ​al.lambourne<στο>rolls-royce.com

Applications, with a detailed CV and letter of application, together with the names and addresses of two referees, should be sent to directly to:

Dr Iain Todd: i.todd<στο>sheffield.ac.uk

Funding Notes:

Students receive funding for a fully funded studentship for 3.5 years which overs tuition fees and provides a tax-free stipend of £20,000pa for the duration of the project. This is an excellent opportunity for an enthusiastic first or 2:1 class graduate to develop knowledge and understanding of electromagnetic devices and their use in material science.

Due to the restrictions of funding criteria only UK/EU applicants are eligible for this position.