Professor Stephen GR Brown

Professor Stephen GR Brown

Stephen GR Brown

 

Deputy Head of College of Engineering and Director of Research

Overview

Specialist Subjects: Computational Materials Science

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Research

As deputy director of the pan-Wales ASTUTE project, my main focus is modelling work for numerous materials problems covering a variety of time and length scales. This work has enjoyed close collaboration with UK and European manufacturers.

Some recent and ongoing projects include:

  • Nano scale modelling of ageing of steels using Kinetic Monte Carlo Method (Tata Steel Company)
  • Nano scale modelling of the leaching of Raney-Ni catalytic powders using Kinetic Monte Carlo Method (European Space Agency, CERAM, Johnson-Matthey, Leiden University Holland among others)
  • Micro scale Computational Fluid Dynamics modelling for numerical determination of permeability during dendritic solidification of alloys
  • Micro scale electro chemical modelling of localized corrosion (Tata Steel Company)
  • Micro scale diffusion modelling for Ti alloys (Rolls-Royce plc)
  • Macro scale FD/FE simulation of moisture ingress into CFRP aerospace materials (Airbus UK)
  • Macro scale FE radiative heat transfer modelling (DSTL Farnborough)
  • Macro scale electro-thermo-mechanical modelling of hot-forming, hot-rolling, coiling & several resistance welding processes (Tata Steel Company)
  • Macro scale heat transfer and solidification modelling of casting processes (several Welsh-SMEs via ASTUTE project)
  • Discrete Element Modelling of Granular Flow for Blast Furnace and Granular Material Transport (Tata Steel Company)

New project work has now begun involving Lattice-Boltzmann Modelling of Additive Layer Manufacturing (new EU-FP7 Research Project with European Space Agency).

Selected publications

Teaching

  • EG-292 - Modelling and Simulation of Materials (14/15)
  • EG-380 - Computational Materials 2 (14/15)

Research theses supervised

PhD

  • 2014 - High throughput methodologies and materials characterisation and materials characterisation for the optimisation and discovery of new alloys. (1st Supervisor: Dr Nicholas Lavery)
  • 2012 - Computational modelling of hydrogen embrittlement of pulse plated nickel (1st Supervisor: Dr Thomas Croft)
  • 2010 - Simulation for Additive Layer Manufacturing and Design (1st Supervisor: Professor Johann Sienz)
  • 2010 - 'On-cooling property and microstructure studies' (1st Supervisor: Dr Karen Perkins)
  • 2010 - Characterising the corrosion-fatigue behaviour of a nickel alloy for disc rotor applications in an air-S02 environment (1st Supervisor: Dr Karen Perkins)
  • 2009 - 'Characterisation and Evolution of the Grain Boundary Network in BCC Metals' (1st Supervisor: Professor Valerie Randle)
  • 2009 - 'Joining, Repair and Strructural Integrity of IN718 Aerospace Material' (1st Supervisor: Dr Karen Perkins)
  • 2009 - 'On the effects of special boundary geometries on intergranular corrosion and grain boundary evolution in aluminium' (1st Supervisor: Professor Valerie Randle)
  • 2009 - 'Modelling of Water Absorption into Carbon Fibre/Epoxy Composites' (1st Supervisor: Dr John Arnold)
  • 2006 - Relating moisture ingress to component strength for carbon-fibre composites (2nd Supervisor: Dr John Arnold)
  • 2006 - Finite element approach for relating moisture ingress to strength in composite materials (2nd Supervisor: Professor Martin Bache)
  • 2005 - A New Design Methodology for composite materials exposed to humid, high temperature environments (2nd Supervisor: Professor Martin Bache)
  • 2004 - Hydrodynamics of surfboard fins (2nd Supervisor: Professor Georgios Fourlaris)
  • 2002 - Finite Element Modelling and Experimental Validation in Radiative Heat Transfer (2nd Supervisor: Dr Nicholas Lavery)
  • 2002 - Microstructure-mechanical Property relationships in novel High Strength Low Alloy Strip Steels (1st Supervisor: Professor Georgios Fourlaris)
  • 2002 - Development of Novel IF strip steel grades (1st Supervisor: Professor Georgios Fourlaris)

EngD

  • 2013 - Development of multi-scale and multi-physical models of the ALM process (1st Supervisor: Dr Nicholas Lavery)
  • 2012 - Computational Modelling and Verification of the ALM Melt Pool (2nd Supervisor: Professor Johann Sienz)
  • 2011 - Lifing Methods Against Rotor Overspeed Failure in Disc Alloys (1st Supervisor: Dr Mark Whittaker)
  • 2011 - A multi-physic approach to the improvement and optimisation of manufacturing processes involving the mixing/interaction of fluids, by utilising Computational Fluid Dynamics (CFD) (1st Supervisor: Professor Oubay Hassan)
  • 2011 - Impact of wear damage on the fatigue performance of disc alloys in gas turbine (1st Supervisor: Dr Mark Whittaker)
  • 2010 - Effective computer simulations of hot-forming process for boron steels to support steel development, process understanding and automotive applications deployment (2nd Supervisor: Professor Georgios Fourlaris)
  • 2010 - A numerical simulation of particulate distribution of the blast furnace raw material burden through the Paul Worth Bell-less Top apparatus (2nd Supervisor: Professor Georgios Fourlaris)
  • 2010 - Effect of SOx and chlorine on crack growth behaviour of a nickel alloy for disc applications (1st Supervisor: Dr Karen Perkins)
  • 2010 - TMF and bithermal crack growth (1st Supervisor: Dr Mark Whittaker)
  • 2010 - Novel testing techniques to characterise advanced structural materials (1st Supervisor: Professor Martin Bache)
  • 2010 - The mechanical characterisation of a high strength, highly creep resistant steel for shaft applications (1st Supervisor: Dr Karen Perkins)
  • 2010 - Improved creep models for nickel based disc alloys (1st Supervisor: Dr Mark Whittaker)
  • 2010 - Understanding the contributions of oxidation damage, mean stress and surface condition on the fatigue crack initiation behaviour of a nickel disc alloy as a result of thermal exposure at elevated temperatures (1st Supervisor: Professor Martin Bache)
  • 2010 - Small scale characterisation of novel aero-engine alloys (1st Supervisor: Professor Martin Bache)
  • 2010 - 'New generation advanced high strength steels for automotive hot stamping technologies' (1st Supervisor: Professor Georgios Fourlaris)
  • 2009 - '''In-service application of composite repair solution''' (2nd Supervisor: Dr John Arnold)
  • 2009 - 'The effect of hot mill through-process temperatures variability on whole coil property variability of AHSS' (2nd Supervisor: Professor David Worsley)
  • 2009 - 'The analysis of bonded repair solutions for primary composite aircraft structures' (1st Supervisor: Professor Johann Sienz)
  • 2007 - Investigation on the metallurgical principles of solid state welding of tinplate. (2nd Supervisor: Professor Georgios Fourlaris)
  • 2007 - 'Hot Rolled Multiphase Steels' (1st Supervisor: Professor Georgios Fourlaris)
  • 2005 - Modelling of blast furnace operations. (2nd Supervisor: Dr Mark Evans)
  • 2005 - Simulation of industrial granular flow and its effect on the sintering process (2nd Supervisor: Dr Mark Evans)
  • 2004 - Modelling of the resistance spot welding process of sheet steel products (2nd Supervisor: Professor Georgios Fourlaris)
  • 2004 - Electro-thermo-mechanical finite modelling of the high speed resistance seam welding process (2nd Supervisor: Professor Georgios Fourlaris)
  • 2004 - Influence of prior particle boundary structure and deformation on the microstructure and mechanical properties of a powder metallurgy nickel alloy for aero-engine disc applications. (1st Supervisor: Professor Martin Bache)
  • 2003 - Modelling of the Bake Hardening Sequences in Novel Interstitial Free Bake Hardening Steels For Automotive Applications (1st Supervisor: Professor Georgios Fourlaris)
  • 2001 - Computer Modelling of Microstructure in Hot Dip Zinc Alloy Coatings (2nd Supervisor: Professor Hamilton Mcmurray)
  • 2001 - Thermal Modelling of High Speed Resistance Welding (2nd Supervisor: Professor David Worsley)
  • 2001 - Mathematical modelling of heat transfer during the hot rolling of steel strip (2nd Supervisor: Professor Brian Wilshire)
  • 2000 - The relationship between metallurgical properties and the crash performance of automotive structures (1st Supervisor: Professor Georgios Fourlaris)

MPhil

  • 2009 - 'Modelling of Water Absorption into Carbon Fibre/Epoxy Composites' (1st Supervisor: Dr John Arnold)

MRes

  • 2012 - 'The utilisation of infrared technology to measure temperature of cobalt and nickel based alloys' (2nd Supervisor: Dr Amitabha Das)
  • 2011 - Optimisation of mechanical properties of continuously annealed IF steels (1st Supervisor: Professor Georgios Fourlaris)
  • 2011 - Melt removal developments for improved blast furnace operations (1st Supervisor: Professor Georgios Fourlaris)
  • 2011 - Steel Technology (1st Supervisor: Professor Georgios Fourlaris)
  • 2011 - Steel Technology (1st Supervisor: Professor Georgios Fourlaris)
  • 2011 - Develop a technical standard for aging characteristics of bake hardenable galvanised steel (1st Supervisor: Professor Georgios Fourlaris)
  • 2010 - 'Evaluation of rolling capability for various electrical steel grades at Port Talbot hot mill for the use in the power industry' (1st Supervisor: Professor Georgios Fourlaris)
  • 2010 - 'Acceptance and commissioning of an automated optical emission spectrometer for process control at an integrated steelworks' (1st Supervisor: Professor Georgios Fourlaris)
  • 2010 - Refractories and their application used in Steel making (1st Supervisor: Professor Georgios Fourlaris)
  • 2010 - 'Effect of roller levelling on tinplate and chrome plated strip shape' (1st Supervisor: Professor Georgios Fourlaris)
  • 2009 - '''In-service application of composite repair solution''' (2nd Supervisor: Dr John Arnold)
  • 2009 - 'The analysis of bonded repair solutions for primary composite aircraft structures' (1st Supervisor: Professor Johann Sienz)
  • 2009 - The Effects of Mixed Liquids on the Stiffness of Carbon Fibre Reinforced Composites (1st Supervisor: Dr John Arnold)
  • 2009 - 'Non-Metallic Inclusions : Development of a Fast Characterisation Technique at Port Talbot Works' (1st Supervisor: Professor Georgios Fourlaris)
  • 2009 - 'Process Optimisation for Galvaised Structural Products' (1st Supervisor: Professor Georgios Fourlaris)
  • 2009 - 'Hot Rolling a New Steel Grade for DWI Tinplate Applications' (1st Supervisor: Professor Georgios Fourlaris)
  • 2009 - '''Failure reduction and increased reliability in continuous casting within Port Talbot Steel Works, the true cost of poor lubrication practices''' (1st Supervisor: Professor Georgios Fourlaris)
  • 2009 - 'Combustion of Granulated Coal in Blast Furnace' (1st Supervisor: Professor Georgios Fourlaris)
  • 2009 - 'Positive release of hot-dip galvanised automotive material to prevent coating adhesion failure at customer' (1st Supervisor: Professor Georgios Fourlaris)
  • 2008 - Determination of diffusion coefficients for water in CFRP in different orientations (2nd Supervisor: Dr John Arnold)
  • 2008 - The effect of absorbed moisture on the bearing strength of carbon fibre composites (2nd Supervisor: Dr John Arnold)
  • 2008 - Characterisation of a new through-thickness tensile test for CFRP (1st Supervisor: Dr John Arnold)
  • 2008 - Design and Optimization of Joints in a Carbon Fibre Bicycle Frame (1st Supervisor: Professor Johann Sienz)
  • 2008 - - Carbonaceous Material Selection - refractory lining integrity/performance/concept - Heat transfer/temperature profile across the hearth - FEM Modelling - Stress/Strain behaviour analysis generated in the refractory lining- effects on furnace shell / tuyere holder etc - Analysis of thermal expansion requirements against design allowances - Interface between Refractory design and cooling system - Process / operational effects on hearth stability - Hearth wear rate - monitoring techniques - NDT / Physical Core Drilling (1st Supervisor: Professor Georgios Fourlaris)
  • 2008 - Investigation of Yield Improvement through Crop Optimisation in the Port Talbot Hot Strip Mill (1st Supervisor: Professor Georgios Fourlaris)
  • 2008 - 'Process Control Information, Operation and Management Systems Upgrades and Enhancements at the TATA Steel UK Port Talbot site Blast Furnaces' (1st Supervisor: Professor Georgios Fourlaris)
  • 2008 - 'Imrproving the Capability of Manufacturing Low Sulphur Strip Steels without the use of a Synthetic Slag' (1st Supervisor: Professor Georgios Fourlaris)
  • 2008 - 'Investigation onto Heat Transfer in the Mould for Continuously Cast Steel Slabs and the Impact on Steel Surface Quality' (1st Supervisor: Professor Georgios Fourlaris)
  • 2008 - 'Blast Furnace Stove Optimisation and Automated Enrichment Control' (1st Supervisor: Professor Georgios Fourlaris)
  • 2008 - ''Investigation into the Effect of the Peripheral Distributor Road Development on Concentrations of Particulate Matter <10┬Ám within the Port Talbot Air Quality Management Area'' (1st Supervisor: Professor Georgios Fourlaris)
  • 2008 - 'Assessment of the Capability of the Exit Shear at the CAPL line to cut 2 mm gauge HSLA and dual phase steels' (1st Supervisor: Professor Georgios Fourlaris)
  • 2007 - An Assessment of the New Materials Being Considered for Gas Turbine Aero-engines and Their Contribution Towards the ACARE Targets. (2nd Supervisor: Professor Georgios Fourlaris)
  • 2007 - Life Cycle and Techno-Economic analysis of industrial sponge nickel catalysts used in hydrogenation reactions (2nd Supervisor: Professor Georgios Fourlaris)
  • 2007 - Life Cycle Analysis. (2nd Supervisor: Professor Georgios Fourlaris)
  • 2007 - Application of Thermal Desorption within Tata Steel Strip Products UK (1st Supervisor: Professor Georgios Fourlaris)
  • 2007 - Developing the Infrared Slag Detection System at the BOS Plant, Port Talbot Steel Works (1st Supervisor: Professor Georgios Fourlaris)
  • 2006 - Hot Rolling of Dual Phase 600 Strip Steel on Llanwern Hot Strip Mill. (1st Supervisor: Professor Georgios Fourlaris)
  • 2006 - Prevention of Transverse Cracking in Niobium Micro-alloyed Continuously Cast Steel Slabs (1st Supervisor: Professor Georgios Fourlaris)
  • 2006 - Investigation into the fitness of and influence of plant weighing systems on through-process yield from BOS vessel inputs to cast slab (1st Supervisor: Professor Georgios Fourlaris)
  • 2006 - Development of a processing route for producing galvanised dual phase steel at the zodiac galvanising line (1st Supervisor: Professor Georgios Fourlaris)
  • 2006 - Control of Galvanised Strip Surface Roughness Through Temper Mill at ZODIAC (1st Supervisor: Professor Georgios Fourlaris)
  • 2005 - Weld Repair of Castings. (2nd Supervisor: Professor Georgios Fourlaris)

MSc

  • 2010 - Optimisation of Grade 6 cobalt based powder in terms of particle size for laser cladding in the steel industry. (1st Supervisor: Professor Georgios Fourlaris)