Advanced manufacturing encompasses the wide range of processes that consist of ‘3D printing’ of metallic materials. This can include such powder bed methods as Electron Beam Melting (EBM) and Direct Laser Deposition (DLD), two modern build technologies that offer significant potential for lean manufacture and a capability to produce near-net shaped final components. A key limitation of these techniques is microstructural control in relation to a number of key process variables. For instance the manufacture of intricate geometries will result in variable thermal cycles and thus a transient microstructure throughout, leading to a highly textured structure. As such, successful implementation of these technologies requires a comprehensive assessment of the relationships of the key process variables, geometries, resultant microstructures and mechanical properties. The nature of these processes suggest that it is often difficult to produce representative test specimens in order to achieve a full mechanical property characterisation. Therefore, the use of small scale test techniques may be exploited, specifically the small punch (SP) test. The SP test offers a capability for sampling miniaturised test specimens from various discrete locations, allowing a full characterisation across a complex component. In addition, SP results may be tentatively correlated to more conventional test approaches. Ongoing research aims to provide support in working towards development and validation strategies in order for advanced manufactured components to be safely implemented in future gas turbine applications. This research is funded by EPSRC and Rolls-Royce as part of the Strategic Partnership in Structural Materials.

Areas of Expertise

  • Miniaturised Testing
  • Additive Layer Manufacturing (ALM) processes
  • Nickel Superalloys (single crystals, polycrystalline)
  • Thermo-mechanical Fatigue
  • Fatigue Lifing
  • Failure Analysis
  • Non-Destructive Evaluation
  • Titanium Alloys

Publications

  1. & The influence of phase angle, strain range and peak cycle temperature on the TMF crack initiation behaviour and damage mechanisms of the nickel-based superalloy, RR1000. International Journal of Fatigue
  2. & High Temperature Deformation Mechanisms in a DLD Nickel Superalloy. Materials 10(5), 457
  3. & Structural Integrity of an Electron Beam Melted Titanium Alloy. Materials 9(6), 470
  4. & Modelling the small punch tensile behaviour of an aerospace alloy. Materials Science and Technology, 1-9.
  5. & The contribution of small punch testing towards the development of materials for aero-engine applications. Theoretical and Applied Fracture Mechanics 86, 69-77.

See more...

Teaching

  • EG-163 Design and Laboratory Classes 1

    .

  • EG-283 Mechanical Deformation in Structural Materials

    Following on from the first year module "Mechanical Properties" this module provides further detail about the deformation characteristics of a wide range of engineering materials. The course aims to develop the understanding of topics taught in the first year module by application to high performance materials such as titanium and nickel. Further understanding of deformation and damage mechanisms is gained through targeted units on elasticity, plasticity, alloy strengthening, fatigue and creep. The knowledge provided then allows for topics such as methods of mechanical testing and additive layer manufacturing. The module then seeks to draw these topics together by considering application to three main material classes, metals, ceramics and composites

  • EG-287 Materials Practicals 2b: Applied examples in polymeric and metallic materials

    Materials Practicals 2b: Applied examples in polymeric and metallic materials - identification and assessment of microstructures of a variety of non-ferrous alloys and polymeric materials. The module will explore the link between microstructure and mechanical properties and show how processing treatments can radically alter the microstructure and behaviour of materials.

  • EGA306 Mechanical Deformation in Structural Materials

    The course aims to develop the understanding of basic material properties by application to high performance materials such as titanium and nickel which are relevant to the medical engineering field. Understanding of deformation and damage mechanisms is gained through targeted units on elasticity, plasticity, alloy strengthening, fatigue and creep. The knowledge provided then allows for topics such as methods of mechanical testing and additive layer manufacturing. The module then seeks to draw these topics together by considering application to three main material classes, metals, ceramics and composites

  • EGTM76 Professional Development for Engineers

    Professional skills can be defined as the transferable skills needed by an individual to make them `employable¿. Along with good technical understanding and subject knowledge, employers often outline a set of skills that they desire from an employee. These skills are what they believe will equip the employee to carry out their role to the best of their ability. Employability depends on your knowledge, skills and attitudes, how you use those assets, and how you present them to employers. This module will introduce a range of professional skills, the importance of them and how they can be developed and enable the student to assess his/her own weaknesses and strengths in terms of individual and team working environments.

Supervision

  • Small scale testing on additive structures (current)

    Student name:
    EngD
    Other supervisor: Prof David Worsley
  • Microstructure-Mechanical property relationships in powder bed laser deposits (current)

    Student name:
    EngD
    Other supervisor: Prof David Worsley
  • Microstructure-Mechanical property relationships in electron beam melted Ti Alloys (current)

    Student name:
    EngD
    Other supervisor: Prof David Worsley
  • Quantification of the microstructure and metallurgical properties of complex forging alloys (current)

    Student name:
    MSc
    Other supervisor: Dr Mark Whittaker
  • Quantification of the Microstruture and metallurgical properties of complex nickel forging alloys (current)

    Student name:
    MSc
    Other supervisor: Dr Mark Whittaker
  • Quantifying deformation in high temperature materials using digital image correlation (DIC) (current)

    Student name:
    EngD
    Other supervisor: Dr Soran Birosca
  • Small scale testing of high `y` nickel based superalloys maufactured by ALM (current)

    Student name:
    EngD
    Other supervisor: Dr Karen Perkins
  • Thermo-mechanical fatigue in single crystals (current)

    Student name:
    PhD
    Other supervisor: Prof David Worsley
  • NDE Characterisation Techniques for Additive Metal Materials & Structures (current)

    Student name:
    PhD
    Other supervisor: Prof Geraint Williams
  • Untitled (current)

    Student name:
    EngD
    Other supervisor: Dr Spencer Jeffs
  • Untitled (current)

    Student name:
    EngD
    Other supervisor: Dr Mark Whittaker
  • Untitled (current)

    Student name:
    EngD
    Other supervisor: Dr Helen Davies
  • Untitled (current)

    Student name:
    PhD
    Other supervisor: Dr Mark Whittaker

Career History

Start Date End Date Position Held Location
2015 Present Senior Lecturer Materials Research Centre, Swansea University
2013 2015 Institute of Structural Materials (ISM) Lecturer Materials Research Centre, Swansea University
2012 2013 Senior Research Officer Materials Research Centre, Swansea University
2011 2012 Senior Project Leader Non-Destructive Validation Centre, TWI
2007 2011 Research Officer Materials Research Centre, Swansea University

Key Grants and Projects

  • Horizon 2020 Framework programme – ‘DevTMF’ (Development of Experimental Techniques and Predictive Tools to Characterise Thermo-Mechanical Fatigue Behaviour and Damage Mechanisms) 2015

    , £704,061

  • National Research Network (NRN) – PhD studentship funding to assess the application of Non-Destructive Test Methods to Advanced Manufactured Components 2015 0

    , £60,000

  • EPSRC/Rolls-Royce – Strategic Partnership in Structural Metallic Systems for Advanced Gas Turbine Applications Core Research 2014

    , £25,000,000

  • National Research Network (NRN) – PhD studentship funding to investigate the effect of TMF on single crystal materials 2014

    , £60,000

  • EPSRC/Rolls-Royce – Strategic Partnership EngD 2014

    , £120,000

  • NSA Welsh Government – Materials Live, a Welsh National Science Academy project designed to increase the awareness of the subject to children of all ages 2013

    , Total Project value = £160k

  • EPSRC/Rolls-Royce – Strategic Partnership EngD 2013

    , £120,000

  • Successful research proposals to EPSRC for specialist thermal imaging equipment 2012

    , £10,000

External Responsibilities

  • Guest Editor, Materials special edition – “Failure Analysis in Materials”

    2015 - Present

  • Secretary, IOM3 Structure & Properties of Materials Committee

    2014 - Present

  • Member, BSi ISE/101/01 Uniaxial Testing committee

    2016 - Present

  • Scrutineer, Engineering Chartership Applications on behalf of IOM3

    2015 - Present

  • Professional Member, IOM3 (MIMMM)

    2015 - Present

  • Fellow, Higher Education Academy (FHEA)

    2016 - Present

  • Reviewer, 7 International Journals including Materials & Design

    2008 - Present

  • External Examiner, PhD/EngD examinations at Birmingham University

    2015 - Present

Awards And Prizes

Date Description
2015 Awarded Chartered Engineer status
2004 Armourers & Brasiers Medal and Prize (Overall excellence in metallurgy)
2004 Worshipful Company of Tinplate Workers (Best results in metallurgy exams)

Academic History

Date Qualification Location
2016 Postgraduate Certificate in Teaching in Higher Education (PGCtHE)

Administrative Responsibilities

  • Materials Research Centre representative - College of Engineering’s Ethics Committee

    2015 - Present