R Kay

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.

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.