Additive manufacture of engineering steels using flux-cored wire

Metallic additive manufacture (AM) is an exciting emerging technology that is changing the way advanced engineering structures are made.

This project is the first time that flux-cored wires have been explored for next generation additive manufacturing of advanced materials for automotive, aerospace and defence applications.

Start date
1 October 2019
47 months
Application deadline
Funding source
The project is funded by the EPSRC and the sponsor, Corewire
Funding information

Directly Funded Project (European/UK Students only)


Corewire Ltd manufacture flux-cored wire welding consumables. They also manufacture equipment which uses these wire consumables to repair and resurface a variety of high wear resistance steel components. This includes dies for the manufacture of automotive components and rolls used in the production of rolled metal.

This project will explore how this current technology and capability can be evolved into additive manufacturing of full components. A key thread will be establishing and quantifying the specific challenges to moving from resurfacing by depositing a few layers of weld metal to full component manufacture using tens or even hundreds of layers. The project will therefore commence with the deposition of current resurfacing solutions (first six months) and progress with the manufacture of increasingly challenging steels and prototypical components. The challenges include higher performance steels, increased reinforcement, compositional grading, more complex geometry, etc. The research programme will include microstructural characterisation, experimental stress-strain measurement, modelling of stress-strain accumulation during additive manufacture and alloy development. High wear resistance steels will be the focus of the research programme and the research is likely to include some wear evaluation and fracture toughness testing.

Alongside the scientific, technological and engineering programme the project will work with a range of existing customers and new industrial partners to identify specific applications of this emerging additive manufacturing capability.

This project is an Engineering Doctorate – you will be based at the sponsor premises in Aldershot, Hampshire for around 80 per cent of the programme time, returning to the University for meetings and lectures.

Related links
Centre for Doctoral Training (CDT) in MiNMaT (Micro- and NanoMaterials and Tech… Corewire Ltd

Eligibility criteria

We requires a minimum of a First or a 2:1. A masters degree is also acceptable with a minimum of a merit although a distinction is preferred.

If English is not your first language, you will need to have an IELTS score of 6.5 or higher.

Please note that the funding partner, the EPSRC has residency criteria. All applications are assessed on an individual basis.

How to apply

Applications for this studentship are now closed.

Please email the Centre Manager, Noelle Hartley with an expression of interest.

We will then liaise directly with you for the next steps.

This position has been filled.

Application deadline

Contact details

Noelle Hartley
05 AB 03
Telephone: +44 (0)1483 683467

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