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PhD Studentship: NSF Swarf – A Novel Forging Process for Closed-Loop Recycling of Metallic Swarf University of Warwick in United Kingdom

Degree Level

PhD

Field of study

Mechanical Engineering

Funding

Available

Deadline

Nov 25, 2026

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Country

United Kingdom

University

University of Warwick

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Keywords

Mechanical Engineering
Materials Science
Metallurgy
Stainless Steel

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About this position

The University of Warwick is offering a PhD studentship on NSF Swarf: A Novel Forging Process for Closed-Loop Recycling of Metallic Swarf. This project sits within the Advanced Steel Research Team and explores how machining waste can be transformed back into valuable material through a patented near-solidus forging approach.

Machining can remove 60–90% of a component’s material, creating large amounts of swarf that are often discarded and mixed with lower-grade waste. The Warwick process proposes pre-compacting swarf, heating it to just below the material’s melting point, and deforming it so that the particles fuse together. If successful, this method could enable high-purity metallic swarf to be recycled directly into forged blanks with a much lower carbon footprint than conventional recycling routes.

The research is strongly materials- and processing-oriented. The successful PhD researcher will establish the process window across several materials, investigate how temperature, forging rate, and strain affect consolidation, and assess whether the patented material properties are achieved. A range of forging dies will be designed to allow processing of different shapes and strain conditions. The project will also support the commercialisation of the process by evaluating metallurgical quality, product consistency, and performance.

Key research themes include understanding forging microstructures and forging types, carrying out hands-on near-solidus forging under varied conditions, and performing microstructural and mechanical characterisation of forged components. There is also potential for complementary modelling to predict strain pathways for different geometries. The project is well suited to a candidate interested in metallic materials, forging science, process optimisation, sustainability, and industrially relevant advanced manufacturing.

The studentship is based at the University of Warwick, UK. Funding information listed is £21,805. The advertised start date is 1 March 2027 at the latest, and the application deadline is 25 November 2026. For enquiries about the position or application procedure, contact Dr. Carl Slater or Sumit Hasra via the emails provided in the advert.

Funding details

Available

What's required

A talented, motivated candidate is sought. The posting does not specify a required degree classification, prior qualifications, or English language test scores, but strong interest in metallic materials, forging, microstructural and mechanical characterisation, and possibly modelling for strain pathways would be advantageous.

How to apply

Apply via the University of Warwick research degrees vacancies page. For informal enquiries about the position or application procedure, contact Dr. Carl Slater or Sumit Hasra by email.

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