Process monitoring system for Robotic Wire Arc Additive Manufacturing (Robotic-WAAM)

Apply and key information

This project is funded by:

Department for the Economy (DfE)
Vice Chancellor's Research Scholarship (VCRS)

Summary

Robotic-Wire Arc Additive Manufacturing (Robotic-WAAM) is one of the AM processes that has wide applicability in large-structure manufacturing, modifying/adding structural features and repairing high value components like die, moulds and gears. However, Robotic-WAAM built components are still subjected to various issues such as dimensional accuracy, defects, surface finish and residual stresses. Manufacturing defective parts with these issues can result in wasted materials, increased power consumption, longer manufacturing times, and elevated production costs.

The chance of producing defective parts increases if the process lacks monitoring and controlling, even the process is operated under optimal conditions. This project aims to address the issues faced by Robotic-WAAM by developing an advanced real-time process monitoring system integrated with Robotic-WAAM machine and experimentally observing the picture of deposition process. The monitoring technology will be used for optimising tool path planning of Robot to ensure a higher quality deposition. A real-time position based closed loop system to capture deposition profile will be used to making intelligent decisions to control Robotic-WAAM process parameters. This will also help in planning effective strategies to reduce defects, minimise surface roughness and residual stresses.

The successful candidate will get an opportunity to work on the state-of-the-art Robotic-WAAM machine, on-site metallurgical facilities, and advanced monitoring equipment using state-of-the-art High Dynamic Range (HDR) thermal imaging, melt pool monitoring cameras. In addition, the candidate will gain significant knowledge and skills in using Robotic-WAAM, robot programming, optimised tool path planning and analysing the deposition quality through process monitoring system.

Essential criteria

Applicants should hold, or expect to obtain, a First or Upper Second Class Honours Degree in a subject relevant to the proposed area of study.

We may also consider applications from those who hold equivalent qualifications, for example, a Lower Second Class Honours Degree plus a Master’s Degree with Distinction.

In exceptional circumstances, the University may consider a portfolio of evidence from applicants who have appropriate professional experience which is equivalent to the learning outcomes of an Honours degree in lieu of academic qualifications.

Experience using research methods or other approaches relevant to the subject domain
A comprehensive and articulate personal statement

Desirable Criteria

If the University receives a large number of applicants for the project, the following desirable criteria may be applied to shortlist applicants for interview.

First Class Honours (1st) Degree
Masters at 65%
Publications - peer-reviewed

Equal Opportunities

The University is an equal opportunities employer and welcomes applicants from all sections of the community, particularly from those with disabilities.

Appointment will be made on merit.

Funding and eligibility

This project is funded by:

Department for the Economy (DfE)
Vice Chancellor's Research Scholarship (VCRS)

Our fully funded PhD scholarships will cover tuition fees and provide a maintenance allowance of £19,237 (tbc) per annum for three years (subject to satisfactory academic performance). A Research Training Support Grant (RTSG) of £900 per annum is also available.

These scholarships, funded via the Department for the Economy (DfE) and the Vice Chancellor’s Research Scholarships (VCRS), are open to applicants worldwide, regardless of residency or domicile.

Applicants who already hold a doctoral degree or who have been registered on a programme of research leading to the award of a doctoral degree on a full-time basis for more than one year (or part-time equivalent) are NOT eligible to apply for an award.

Due consideration should be given to financing your studies.