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. & The three-prong method: a novel assessment of residual stress in laser powder bed fusion. Virtual and Physical Prototyping, 1-6.
  2. & A novel High-Entropy Alloy-based composite material. Journal of Alloys and Compounds 730, 544-551.
  3. & (2017). A Study into the Effects of Gas Flow Inlet Design in a Renishaw AM250 Laser Powder Bed Fusion Machine using Computational Modelling. Presented at 2017 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2017), Austin, Texas, USA: 2017 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2017).
  4. & (2017). Controlling Thermal Expansion with Lattice Structures using Powder Bed Laser Fusion. Presented at 2017 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2017), Austin, Texas, USA: 2017 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2017).
  5. & (2017). The Assessment of Residual Stress in Powder Bed Fusion Components Using a Novel Residual Stress Analysis Component, the Three Prong Method. Presented at 2017 Solid Freeform Fabrication Symposium Proceedings (SFF Symp 2017), Austin, Texas, USA: 2017 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2017).

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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

  • Steel Technology (current)

    Student name:
    MRes
    Other supervisor: Prof David Worsley
  • Physical Verification of the Melt Pool in Powder Bed Laser Fusion for Computational Validation (current)

    Student name:
    EngD
    Other supervisor: Dr Nicholas Lavery
  • Microstructural & Product Performance Assessment of AHSS & UHSS (current)

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

    Student name:
    EngD
    Other supervisor: Dr Nicholas Lavery
  • The effect of alkali loading on Blast Furnace stability at Port Talbot Strip Products UK (current)

    Student name:
    MRes
    Other supervisor: Prof David Worsley
  • Steel Technology (current)

    Student name:
    MRes
    Other supervisor: Prof David Worsley
  • '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
  • 'Electrolytic Codeposition of a Luminescent Nickel Composite for Coin Security' (current)

    Student name:
    MRes
    Other supervisor: Dr Amit Das
  • 'Measurement and data visualisation of meniscus stability in the continuous casting mould' (current)

    Student name:
    MRes
    Other supervisor: Dr Amit Das
  • Interdisciplinary Mechanical-Manufacturing–Material Informatics (current)

    Student name:
    PhD
    Other supervisor: Dr Sathiskumar Jothi
  • Computational modelling and validation of thermal and flow aspects of the powder bed fusion process (current)

    Student name:
    EngD
    Other supervisor: Dr Nicholas Lavery
  • Analysis of the Effects of Extended Powder re-use in Powder Bed Laser Fusion. (current)

    Student name:
    PhD
    Other supervisor: Dr Nicholas Lavery
  • 'Scandium Metal Processing for Aerospace Application' (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
  • 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
  • Hydrogen Embrittlement of Automotive Ultra High Strength Steels – Mechanism & Minimisation: (current)

    Student name:
    EngD
    Other supervisor: Dr Sathiskumar Jothi
  • 'Investigation into the mechanical properties and microstructure of stainless steel 316L additively manufactured parts' (current)

    Student name:
    PhD
    Other supervisor: Prof Johann Sienz
  • Numerical modelling and experimental verification of investment casting process. (current)

    Student name:
    EngD
    Other supervisor: Dr Nicholas Lavery
  • Untitled (current)

    Student name:
    EngD
    Other supervisor: Dr Nicholas Lavery
  • Untitled (current)

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

    Student name:
    EngD
    Other supervisor: Dr David Penney
  • ''Investigation of gauge measurement errors for Hartlepool Tube material'' (awarded 2017)

    Student name:
    MRes
    Other supervisor: Dr Amit Das

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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