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 a Professor in 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 on a range of EU-funded projects in FP5 (e.g. SmartWeld) and FP6 (e.g. ALCAS) including coordination of 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. Professor Brown is also a member of the Technical Evaluation Panel for the recently created Metallurgy Europe Eureka project.

Current collaborative research with UK and international companies includes advanced Discrete Element Modelling of granular flows, Combinatorial Metallurgy approaches for alloy discovery and Additive Manufacturing of metallic components (both modelling and experimentation).

Areas of Expertise

  • Computational Materials
  • Scopus author ID: 55324885200

Publications

  1. & Optimizing gate location to reduce metal wastage: Co–Cr–W alloy filling simulation. Journal of Materials Processing Technology 240, 249-254.
  2. & Increased Corrosion Resistance of Zinc Magnesium Aluminum Galvanised Coating through Germanium Additions. ECS Transactions 75(30), 1-15.
  3. & A numerical investigation assessing the symmetry of burden charging in a blast furnace using different chute designs. Ironmaking & Steelmaking, 1-9.
  4. & Effects of hot isostatic pressing on the elastic modulus and tensile properties of 316L parts made by powder bed laser fusion. Materials Science and Engineering: A 693, 186-213.
  5. & Powder Bed Layer Characteristics: The Overseen First-Order Process Input. Metallurgical and Materials Transactions A 47(8), 3811-3822.

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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

  • Untitled (current)

    Student name:
    EngD
    Other supervisor: Dr Nicholas Lavery
  • Hydrogen Embrittlement of Automotive Ultra High Strength Steels – Mechanism & Minimisation: (current)

    Student name:
    EngD
    Other supervisor: Prof George Fourlaris
  • Development of multi-scale and multi-physical models of the ALM process (current)

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

    Student name:
    EngD
    Other supervisor: Dr Nicholas Lavery
  • 'Simulating the Slide and Roll of a Golf Ball and Investigating the Bouncing Present' (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: Prof George Fourlaris
  • Application of non-spherical discrete element methods to the blast furnace (current)

    Student name:
    EngD
    Other supervisor: Dr David Penney
  • Numerical modelling and experimental verification of investment casting process. (current)

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

    Student name:
    PhD
    Other supervisor: Dr Nicholas Lavery
  • 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
  • Scandium Metal Processing for Space Applications (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
  • 'Investigation into the mechanical properties and microstructure of stainless steel 316L additively manufactured parts' (current)

    Student name:
    PhD
    Other supervisor: Prof Johann Sienz
  • Interdisciplinary Mechanical-Manufacturing–Material Informatics (current)

    Student name:
    PhD
    Other supervisor: Dr Sathiskumar Jothi

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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