Best Practices for Minimising Dross Formation During Melting of Scrap Aluminium Brunel University of London in United Kingdom

The Brunel Centre for Advanced Solidification Technology (BCAST) at Brunel University of London is offering a fully funded PhD position focused on minimising dross formation during the melting of scrap aluminium. This project is conducted in collaboration with Constellium, a global leader in advanced aluminium products, and forms part of the Constellium University Technology Centre (UTC) activities. BCAST is renowned for its expertise in metallurgy and the processing of metallic materials for lightweighting applications.

Dross formation in the aluminium recycling industry leads to significant material losses, with up to 5-10% of the charge lost as dross, which consists of aluminium oxides, impurities, and trapped metal. The project aims to establish best practices for minimising dross formation by optimising preheat treatments, melting cycle parameters, and furnace atmosphere control, as well as introducing specific elements or fluxes to inhibit oxide growth. The research will involve studying the surface characteristics of scrap from various sources and implementing controlled preheat and environmental conditions to reduce oxidation and material loss.

The successful candidate will benefit from close collaboration with both academic researchers at BCAST and industrial engineers at Constellium, providing a strong foundation for a future career in industry or academia. An industrial supervisor from Constellium will also be appointed to support the project.

Applicants should hold or expect to obtain a first or upper-second class honours degree in Materials Science, Mechanical Engineering, Chemical Engineering, Physics, or a related discipline. A strong background in physical metallurgy, materials science, or chemistry is essential, along with experience in casting, heat treatment, microstructural characterisation, and surface chemical analysis. Effective communication skills, motivation, and the ability to work both independently and as part of a team are required. Eligibility for home tuition fees is necessary, and evidence of English language proficiency (IELTS 6.5 overall, minimum 6.0 in all sections or equivalent) must be provided if appropriate.

The studentship includes an annual stipend of approximately £23,000 and covers full-time home tuition fees for up to four years. The application deadline is 30 April 2026. To apply, submit your CV, personal statement, degree certificates and transcripts, evidence of English language skills (if required), and contact details for two referees in a single PDF to Prof. Hari Babu Nadendla at [email protected]. Please state the project title at the top of your personal statement. Interviews will be held shortly after the deadline.