About Me

Professor Stephen Brown is Head of the College of Engineering at Swansea University with a PhD in metallurgy (1986, Swansea University) and has spent his career in the computational modelling of materials processing. He became Professor of Computational Materials Science in 2007.

Apart from UK-centred research projects with various industrial collaborators (e.g. Rolls-Royce, Tata Steel, Airbus/EADS) he has previously worked a range of EU-funded projects in FP5 (e.g. SmartWeld) and FP6 (e.g. ALCAS). He coordinated 14 active partners in the work-package on computational materials modelling in the FP6 IMPRESS project (project value €40million); graded at the top level by two EU assessors. A recently completed FP7 project (concerning multiscale modelling and characterisation for hydrogen-embrittlement problems) was ‘MultiHy’ and Swansea is also part of the current ‘AMAZE’ FP7 project.

As deputy director of the pan-Wales ASTUTE project, the 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.

Areas of Expertise

  • Computational Materials
  • Scopus author ID: 55324885200

Publications

  1. & Powder Bed Layer Characteristics: The Overseen First-Order Process Input. Metallurgical and Materials Transactions A
  2. & Formation and Disruption of W-Phase in High-Entropy Alloys. Metals 6(5), 106
  3. & The Scandium Effect in Multicomponent Alloys. International Materials Reviews
  4. & Combinatorial development and high throughput materials characterisation of steels. Ironmaking & Steelmaking 42(10), 727-733.
  5. & Localized microstructural characterization of a dissimilar metal electron beam weld joint from an aerospace component. Materials & Design 90, 101-114.

See more...

Teaching

  • EG-292 Modelling and Simulation of Materials

    This module details the mathematical descriptions necessary for the simulation of a variety of critical engineering problems, with an emphasis on materials processing. Application of these to heat and mass diffusion, electric fields, fluid dynamics etc is considered. Several case studies of manufacturing processes are included together with consideration of some multiscale phenomena. Module Aims: to provide a detailed understanding of computational simulation methods for modelling materials engineering problems.

  • EG-380 Computational Materials 2

    - Introduction and review of key process variables and microstructural phenomena in manufacturing processes involving liquid/solid phase transformations. - Macroscale continuum models for solidifying systems (casting). - Modelling approaches to other melting/solidification processes (welding/laser methods, including ALM techniques). - Introduction to phase field methods (kinetics, thermodynamics and interfaces). - Phase field modelling of Spinodal decomposition, conservative Cahn-Hilliard approach. - The Allen-Cahn non-conservative equation. - Ginzberg-Landau phase field equations for general microstructural evolution models. - Applications to grain growth (interface controlled), dendritic solidification (anisotropic interfacial terms) and anisotropic Spinodal decomposition (elastic stress effects).

Supervision

  • 'Effect of SOx and chlorine on crack growth behaviour of a nickel alloy for disc applications' (current)

    Student name:
    EngD
    Other supervisor: Dr Karen Perkins
  • 'Tapping Optimisation by drill bit selection' (current)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Application of the wilshire equations to nickel disc alloys with an investigation of the dislocation network' (current)

    Student name:
    EngD
    Other supervisor: Dr Mark Whittaker
  • Application of non-spherical discrete element methods to the blast furnace (current)

    Student name:
    EngD
    Other supervisor: Dr David Penney
  • Computational Modelling and Verification of the ALM Melt Pool (current)

    Student name:
    EngD
    Other supervisor: Dr Nicholas Lavery
  • Development of multi-scale and multi-physical models of the ALM process (current)

    Student name:
    EngD
    Other supervisor: Dr Nicholas Lavery
  • Simulation of golf ball bounce, slide and roll and a puttting stroke (current)

    Student name:
    MSc
    Other supervisor: Dr Iwan Griffiths
  • Develop a technical standard for aging characteristics of bake hardenable galvanised steel (current)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • High throughput methodologies and materials characterisation and materials characterisation for the optimisation and discovery of new alloys. (current)

    Student name:
    PhD
    Other supervisor: Dr Nicholas Lavery
  • Design and Build of Components for a Ventricular Assist Device by Selective Laser Melting (current)

    Student name:
    PhD
    Other supervisor: Dr Nicholas Lavery
  • Scandium Metal Processing for Space Applications (current)

    Student name:
    PhD
    Other supervisor: Dr Nicholas Lavery
  • Controlled thermal expansion metamaterials for lightweight optical applications (NRN145) (current)

    Student name:
    PhD
    Other supervisor: Dr Nicholas Lavery
  • Steel Technology (current)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Experimentation and Simulation for Additive Layer Manufacturing and Design' (current)

    Student name:
    PhD
    Other supervisor: Professor Johann Sienz
  • 'Novel testing techniques to characterise advanced structural materials' (awarded 2016)

    Student name:
    EngD
    Other supervisor: Professor Martin Bache
  • 'Impact of corrosion features on the remnant fatigue life of a nickel alloy for disc rotor applications' (awarded 2016)

    Student name:
    PhD
    Other supervisor: Dr Karen Perkins
  • 'A numerical simulation of particulate distribution of the blast furnace raw material burden through the Paul Worth Bell-less Top apparatus' (awarded 2016)

    Student name:
    EngD
    Other supervisor: Professor George Fourlaris
  • 'Thermo-mechanical fatigue crack growth of a polycrystalline nickel aklloy' (awarded 2015)

    Student name:
    EngD
    Other supervisor: Dr Mark Whittaker
  • 'The mechanical characterisation of a high strength, creep resistant steel for aerospace applications' (awarded 2015)

    Student name:
    EngD
    Other supervisor: Dr Karen Perkins
  • 'The effect of hot mill through-process temperatures variability on whole coil property variability of AHSS' (awarded 2015)

    Student name:
    EngD
    Other supervisor: Professor David Worsley
  • 'The contributions of oxidation, mean stress and surface condition on the fatigue response of RR1000' (awarded 2015)

    Student name:
    EngD
    Other supervisor: Professor Martin Bache
  • 'Lifing Methods Against Rotor Overspeed Failure for Gas Turbine Applications' (awarded 2015)

    Student name:
    EngD
    Other supervisor: Dr Mark Whittaker
  • 'Wear fatigue in nickel superalloys' (awarded 2015)

    Student name:
    EngD
    Other supervisor: Dr Mark Whittaker
  • '''Failure reduction and increased reliability in continuous casting within Port Talbot Steel Works, the true cost of poor lubrication practices''' (awarded 2015)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'The Development of Simulation procedures for industrial mixing processes' (awarded 2015)

    Student name:
    EngD
    Other supervisor: Professor Oubay Hassan
    Other supervisor: Dr Sam Rolland
  • 'Multiscale modelling and experimentation of hydrogen embrittlement in aerospace materials' (awarded 2015)

    Student name:
    PhD
    Other supervisor: Dr Nick Croft
  • '''In-service application of composite repair solution''' (awarded 2014)

    Student name:
    EngD
    Other supervisor: Professor Cris Arnold
  • 'Joining, Repair and Strructural Integrity of IN718 Aerospace Material' (awarded 2014)

    Student name:
    PhD
    Other supervisor: Dr Karen Perkins
  • 'Acceptance and commissioning of an automated optical emission spectrometer for process control at an integrated steelworks' (awarded 2014)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Evaluation of rolling capability for various electrical steel grades at Port Talbot hot mill for the use in the power industry' (awarded 2014)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'On-cooling property and microstructure studies' (awarded 2014)

    Student name:
    PhD
    Other supervisor: Dr Karen Perkins
  • 'Understanding Yield Discrepancies between Slab and Hot Rolled Coil' (awarded 2014)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Effect of roller levelling on tinplate and chrome plated strip shape' (awarded 2014)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Steel Technology (awarded 2014)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'New generation advanced high strength steels for automotive hot stamping technologies' (awarded 2014)

    Student name:
    EngD
    Other supervisor: Professor George Fourlaris
  • Refractories and their application used in Steel making (awarded 2013)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Process Optimisation for Galvaised Structural Products' (awarded 2013)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Combustion of Granulated Coal in Blast Furnace' (awarded 2013)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Positive release of hot-dip galvanised automotive material to prevent coating adhesion failure at customer' (awarded 2013)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Assessment of the Capability of the Exit Shear at the CAPL line to cut 2 mm gauge HSLA and dual phase steels' (awarded 2013)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'The utilisation of infrared technology to measure temperature of cobalt and nickel based alloys' (awarded 2013)

    Student name:
    MRes
    Other supervisor: Dr Amit Das
  • 'The analysis of bonded repair solutions for primary composite aircraft structures' (awarded 2013)

    Student name:
    EngD
    Other supervisor: Professor Johann Sienz
  • 'On the effects of special boundary geometries on intergranular corrosion and grain boundary evolution in aluminium' (awarded 2013)

    Student name:
    PhD
    Other supervisor: Professor Valerie Randle
  • 'Characterisation and Evolution of the Grain Boundary Network in BCC Metals' (awarded 2013)

    Student name:
    PhD
    Other supervisor: Professor Valerie Randle
  • 'Imrproving the Capability of Manufacturing Low Sulphur Strip Steels without the use of a Synthetic Slag' (awarded 2012)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Modelling of Water Absorption into Carbon Fibre/Epoxy Composites' (awarded 2012)

    Student name:
    PhD
    Other supervisor: Professor Cris Arnold
  • 'Investigation onto Heat Transfer in the Mould for Continuously Cast Steel Slabs and the Impact on Steel Surface Quality' (awarded 2012)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Blast Furnace Stove Optimisation and Automated Enrichment Control' (awarded 2012)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • ''Investigation into the Effect of the Peripheral Distributor Road Development on Concentrations of Particulate Matter <10µm within the Port Talbot Air Quality Management Area'' (awarded 2012)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Hot Rolling a New Steel Grade for DWI Tinplate Applications' (awarded 2012)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Process Control Information, Operation and Management Systems Upgrades and Enhancements at the TATA Steel UK Port Talbot site Blast Furnaces' (awarded 2012)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • 'Hot Rolled Multiphase Steels' (awarded 2012)

    Student name:
    EngD
    Other supervisor: Professor George Fourlaris
  • 'Non-Metallic Inclusions : Development of a Fast Characterisation Technique at Port Talbot Works' (awarded 2012)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Investigation of Yield Improvement through Crop Optimisation in the Port Talbot Hot Strip Mill (awarded 2011)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Untitled (awarded 2011)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Application of Thermal Desorption within Tata Steel Strip Products UK (awarded 2011)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Investigation into the fitness of and influence of plant weighing systems on through-process yield from BOS vessel inputs to cast slab (awarded 2011)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Relating moisture ingress to component strength for carbon-fibre composites (awarded 2011)

    Student name:
    PhD
    Other supervisor: Professor Cris Arnold
  • Control of Galvanised Strip Surface Roughness Through Temper Mill at ZODIAC (awarded 2011)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Development of a processing route for producing galvanised dual phase steel at the zodiac galvanising line (awarded 2011)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Developing the Infrared Slag Detection System at the BOS Plant, Port Talbot Steel Works (awarded 2011)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Hot Rolling of Dual Phase 600 Strip Steel on Llanwern Hot Strip Mill. (awarded 2010)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Prevention of Transverse Cracking in Niobium Micro-alloyed Continuously Cast Steel Slabs (awarded 2010)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Finite element approach for relating moisture ingress to strength in composite materials (awarded 2010)

    Student name:
    PhD
    Other supervisor: Professor Martin Bache
  • Modelling of the resistance spot welding process of sheet steel products (awarded 2010)

    Student name:
    EngD
    Other supervisor: Professor George Fourlaris
  • The effect of absorbed moisture on the bearing strength of carbon fibre composites (awarded 2010)

    Student name:
    MRes
    Other supervisor: Professor Cris Arnold
  • Determination of diffusion coefficients for water in CFRP in different orientations (awarded 2010)

    Student name:
    MRes
    Other supervisor: Professor Cris Arnold
  • A New Design Methodology for composite materials exposed to humid, high temperature environments (awarded 2010)

    Student name:
    PhD
    Other supervisor: Professor Martin Bache
  • Characterisation of a new through-thickness tensile test for CFRP (awarded 2010)

    Student name:
    MRes
    Other supervisor: Professor Cris Arnold
  • Design and Optimization of Joints in a Carbon Fibre Bicycle Frame (awarded 2010)

    Student name:
    MRes
    Other supervisor: Professor Johann Sienz
  • Simulation of industrial granular flow and its effect on the sintering process (awarded 2010)

    Student name:
    EngD
    Other supervisor: Dr Mark Evans
  • Life Cycle and Techno-Economic analysis of industrial sponge nickel catalysts used in hydrogenation reactions (awarded 2008)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Electro-thermo-mechanical finite modelling of the high speed resistance seam welding process (awarded 2008)

    Student name:
    EngD
    Other supervisor: Professor George Fourlaris
  • Modelling of the Bake Hardening Sequences in Novel Interstitial Free Bake Hardening Steels For Automotive Applications (awarded 2008)

    Student name:
    EngD
    Other supervisor: Professor George Fourlaris
  • Life Cycle Analysis. (awarded 2008)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • An Assessment of the New Materials Being Considered for Gas Turbine Aero-engines and Their Contribution Towards the ACARE Targets. (awarded 2008)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Hydrodynamics of surfboard fins (awarded 2007)

    Student name:
    PhD
    Other supervisor: Professor George Fourlaris
  • Weld Repair of Castings. (awarded 2006)

    Student name:
    MRes
    Other supervisor: Professor George Fourlaris
  • Untitled (awarded 2004)

    Student name:
    MRes

Research

Ballmill

 

 

 

 

 

 

 

Professor Brown's 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).

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The images are of the following:

  • Full scale Discrete Element Method (DEM) model of a large scale Ball Mill
  • Full scale Discrete Element Method (DEM) model of Nickel pellet production process

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