Transforming Corrosion Resistance of Additively Manufactured Metals Using Electrochemical Surface Engineering University of Leeds in United Kingdom

This fully-funded PhD project at the University of Leeds, in partnership with the Henry Royce Institute and Holdson, is part of cohort 3 of the EPSRC CDT in Developing National Capability for Materials 4.0. The research aims to transform the corrosion resistance of additively manufactured (AM) metals by developing and optimising advanced electrochemical surface engineering techniques, specifically tailored electropolishing processes for AM metal alloys.

Additive Manufacturing offers significant advantages in design flexibility and material efficiency, but surface texture and corrosion resistance remain critical challenges, especially for applications in aerospace, medical, and renewable energy sectors. This project will systematically evaluate the corrosion performance of stainless steel produced via Laser Powder Bed Fusion, comparing various surface treatment approaches under harsh, application-relevant conditions. The collaboration with Holdson, experts in sustainable electropolishing, ensures industrial relevance and access to cutting-edge technology.

A key innovation is the development of high-throughput corrosion screening methods, leveraging multi-material AM components to enable batch electropolishing and rapid electrochemical testing at specific locations. This allows for detailed correlation between local alloy composition, microstructure, and corrosion behaviour. Advanced microscopy will be used for comprehensive surface and material analysis, providing insights into the effectiveness of different treatments.

The project will also integrate high-throughput experimental data into a machine learning framework, aiming to predict optimal electropolishing parameters for various AM metal alloys. This data-driven approach supports industrial implementation and accelerates the adoption of AM in corrosion-critical sectors.

The studentship covers full tuition fees for both home and international students, a tax-free stipend of at least £20,780 (with London allowance if applicable), and a research training support grant. Up to 30% of studentships are available for outstanding international applicants, and early applications are encouraged. The CDT is committed to Equality, Diversity, and Inclusion, welcoming candidates from underrepresented groups.

Applicants should have a strong background in mechanical engineering, materials science, chemical engineering, metallurgy, or a closely related discipline, with a keen interest in additive manufacturing, corrosion science, and electrochemical engineering. For technical queries, contact Dr J Owen at [email protected].

To apply, visit the University of Leeds application portal, select 'research degree - research postgraduate', choose the 2026/27 academic year, and under 'planned course of study', select 'EPSRC CDT Materials 4.0'. The application deadline is March 3, 2026.