The design of new components and alloys is now being performed via an integrated computational and experimental technique called Integrated Computational Materials Engineering (ICME). Prof. Lee has successfully worked with Ford to help develop their Virtual Casting Program to enable rapid and cost-effective development of components, as shown in Fig. 1. The goal of this project is to bring this tool to a new level of aiding the novel engine alloy design via advanced synchrotron x-ray imaging. Nanoscale characterization of strengthening phases in Al and Mg alloys will greatly speed up the development of high performance lightweight, cast alloy(s) capable of exceeding state of the art aluminum engine alloy performance baseline. This project will be an integral part of the Department of Energy funded project on ICME Guided Development of Advanced Cast Aluminum Alloys For Automotive Engine Applications at Ford Motor Company, a key project championed by Obama.

The proposed work is motivated by the fact that the mechanical properties of a large fraction of Al alloys are largely controlled by the morphology of their nano-scale precipitates. Understanding the kinetic mechanisms leading to the very different types of observed precipitate morphologies, coupled with the ability to accurately predict the precipitate size, shape, and habit orientation, promises to provide valuable guidance for designing the chemistry and processing conditions that will dramatically improve mechanical properties. Microstructure modeling is the key component linking chemistry/ processing with properties within the new paradigm of ICME. One of the main objectives of this project is to develop a predictive, efficient, and more accurate computational tool that will incorporate key thermodynamic and kinetic processes at the nano-scale, enabling successful calculation of the evolution of strengthening phases in new generations of Al alloys. With alloy composition and processing conditions as input, the proposed tool can be employed to facilitate the alloy design and mechanical property prediction at a given casting and heat treatment conditions, addressing key manufacture processes applicable to powertrain components.

The student will be based at the Diamond-Manchester Collaboration in Oxfordshire, working with Diamond Light Source and Ford to further develop and validate the powerful ICME tools. The developments will be based on in-situ synchrotron x-ray imaging in real and reciprocal space (i.e. both three-dimensional nano-tomography and small angle x-ray scattering) coupled with atomic probe, involving the measurement of kinetics and thermodynamics of different phase transformation in Al alloys. Synchrotron x-ray has been applied to characterize microstructure evolution and validating many different micro- and nano- structures in various materials. Synchrotron x-ray imaging can provide real time data on nano-structure evolution during casting/heat treatment processes. A complete validation of the new VAC tool for new Al engine alloy development requires two sets of experiments: one is the nano-scale tomography and the other is small angle x-ray scattering to quantify the structural ordering process of the stable or metastable phases in Al alloys.


Funding Notes:

Funding will cover tuition fees and annual maintenance payments of at least £13,726 for eligible UK and EU applicants. EU nationals must have lived in the UK for 3 years prior to the start of the programme to be eligible for a full award (fees and stipend). EU nationals who have lived elsewhere in the EU for the 3 years prior to the start of the programme would be eligible for a fees-only award.

Applicants should have or expect to achieve a First Class or 2.1 degree in a relevant subject.

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