Best Practices for Minimising Dross Formation During Melting of Scrap Aluminium
The Brunel Centre for Advanced Solidification Technology (BCAST) at Brunel University of London is offering a fully funded PhD studentship 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. The research aims to address a significant challenge in the aluminium recycling industry: dross formation, which can result in substantial material losses of up to 5-10% per charge. Dross, composed of aluminium oxides, impurities, and trapped metal, forms due to reactions between molten aluminium and atmospheric oxygen. The project will systematically investigate factors contributing to excessive dross formation, including scrap condition, furnace type, melting cycle parameters, heating sources, and furnace atmosphere.
By studying the surface characteristics of scrap from various sources—such as end-of-life products, machining scrap, and production returns—and implementing controlled preheat and environmental conditions, the research seeks to reduce oxidation and minimise dross formation. The project will establish best practices for remelting aluminium scrap, focusing on optimising preheat treatments, melting cycle parameters, and furnace atmosphere control. Additionally, the introduction of specific elements or fluxes to inhibit oxide growth will be explored. The successful candidate will benefit from close collaboration with both academic researchers at BCAST and industrial engineers at Constellium, including an appointed industrial supervisor. This partnership offers valuable exposure to both academic and industrial research environments, providing a strong foundation for future careers in industry or academia.
Funding for this PhD studentship includes an annual stipend starting from approximately £23,000 and payment of full-time home tuition fees for up to 48 months (4 years). Applicants must have or expect to receive a first or upper-second class honours degree in Materials Science, Mechanical Engineering, Chemical Engineering, Physics, or a related discipline. A postgraduate master’s degree is not required but may be advantageous. Essential skills include a strong background in physical metallurgy, materials science, or chemistry, and experience in casting, heat treatment, microstructural characterisation, surface chemical analysis, and differential scanning calorimetry. Candidates should be highly motivated, able to work independently and collaboratively, and possess effective communication skills. Eligibility for home tuition fees is required, based on nationality, residency, or other connection to the UK. Evidence of English language proficiency to IELTS 6.5 (or equivalent, with 6.0 in all sections) is required if appropriate.
To apply, submit your application documents—including CV, personal statement, degree certificates and transcripts, evidence of English language skills, and contact details for two referees—in one PDF file by noon on 9th March 2026 to [email protected]. Please state the project title at the top of your personal statement. Interviews will be held shortly after the application deadline. For further information or informal discussion, contact Prof. Hari Babu Nadendla at [email protected]. More details about BCAST can be found at
BCAST website
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