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, focuses on transforming the corrosion resistance of additively manufactured (AM) metals through advanced electrochemical surface engineering. As part of cohort 3 of the EPSRC CDT in Developing National Capability for Materials 4.0, the research aims to address a critical barrier in AM: surface texture and its impact on corrosion, especially for applications in aerospace, medical, and renewable energy sectors.

The project will develop and optimise a novel electropolishing process tailored for AM metal alloys, with an initial focus on stainless steel produced via Laser Powder Bed Fusion. Comparative studies of various surface treatments will be conducted, with corrosion testing designed to replicate harsh, real-world conditions relevant to Holdson’s industrial applications. A key innovation is the creation of high-throughput corrosion screening methods, leveraging multi-material AM components to enable batch electropolishing and rapid, location-specific electrochemical testing. This will allow for detailed correlation between local alloy composition, microstructure, and corrosion behaviour, supported by advanced microscopy techniques.

In the final phase, high-throughput experimental data will be used to build a machine learning framework capable of predicting optimal electropolishing parameters for AM metal alloys, facilitating industrial implementation. The project offers a unique opportunity to work at the intersection of materials science, mechanical engineering, and data-driven manufacturing, with strong industrial collaboration and access to state-of-the-art facilities.

The studentship covers full tuition fees (for both home and international students), a tax-free stipend of at least £20,780 per year (plus London allowance if applicable), and a research training support grant. Up to 30% of studentships can be awarded to outstanding international applicants, and candidates from all backgrounds are encouraged to apply. The CDT is committed to Equality, Diversity and Inclusion, and applications from underrepresented groups are strongly encouraged.

Applicants should have a strong background in materials science, mechanical engineering, metallurgy, or a related discipline. For technical or scientific queries, contact Dr J Owen at [email protected]. The application deadline is May 14, 2026. For more information and to apply, visit the University of Leeds application portal and select 'EPSRC CDT Materials 4.0' as your planned course of study.