Additive Manufacture: Optimisation and Characterisation of Additively Manufactured Alloy 625 Thin-Wall Structures (RS977)

Funding Providers: DRIVERS DFA / Rolls-Royce

Subject Area: Materials Science & Engineering

Project Start Dates: October 2026

** (Please see the note below regarding potential later start dates.)

Supervisors:

• Professor Robert Lancaster
•  Professor Spencer Jeffs

Aligned programme of study: Materials Engineering PhD

Mode of study: Full time

Place of study: Swansea University (Bay Campus)

Project title: Optimisation and Characterisation of Additively Manufactured Alloy 625 Thin-Wall Structures

Project description:

Additive manufacturing offers significant opportunities to produce complex, lightweight components that would be difficult to manufacture using conventional methods. One important application is the production of advanced heat exchangers, where thin walls and intricate internal features can improve performance and efficiency.

Alloy 625 is expected to play a major role in future heat-exchanger designs because of its strength, durability and resistance to high-temperature environments. However, the properties of very thin additively manufactured sections are not yet fully understood. Their performance can be affected by the manufacturing process, heat treatment, surface condition, build direction and the transition between thin and thicker regions.

This PhD will provide the scientific understanding and supporting evidence required to design, manufacture and assess these components safely. Starting the project in September 2026 would allow the research to support the wider development programme at an early and important stage.

**In exceptional circumstances, and subject to the discretion of the University and/or the relevant funding body, a deferral of offer may be granted to the next available enrolment period. Such deferral will typically not exceed a duration of three calendar months from the originally stipulated commencement date. Please note that only one deferral may be considered, and any such deferral is not guaranteed.

PhD: Applicants for PhD must hold an undergraduate degree at 2.1 level (or non-UK equivalent as defined by Swansea University) in Engineering or similar relevant science discipline. 

English Language Requirements: 

IELTS 6.5 Overall (5.5+ each comp.) or Swansea University recognised equivalent. Full details of our English Language policy, including certificate time validity, can be found here. 

Note for applicants holding international and/or European qualifications: details of how your qualification compares to the published academic entry requirements can be found on our Country Specific Entry Requirements page. 

If you have questions regarding your academic eligibility based on the above, email pgrscholarships@swansea.ac.uk with the link to the scholarships you are interested in. 

Please note that the programme requires some applicants to hold ATAS clearance, further details on ATAS scheme eligibility are available on the UK Government website. 

ATAS clearance IS NOT required to be held as part of the scholarship application process. Successful award winners (as appropriate) are provided with details as to how to apply for ATAS clearance in tandem with a scholarship course offer.

Due to funding restrictions, this scholarship is open to applicants eligible to pay tuition fees at the UK rate only, as defined by UKCISA (Full list of categories for HE in Wales)

This scholarship covers the full cost of tuition fees and an annual stipend at UKRI rate (currently £21,805 for 2026/27), plus an additional stipend of £5,000 per year.

To apply, please complete the entire application form here.

Applications may be submitted in Welsh and any application submitted in Welsh will be treated no less favourably than an application submitted in English. Please refer to the University’s Welsh Language Policy on Awarding Grants

To be considered for this scholarship award the following steps are also required.

1) In section ‘Programme Related Information’ please input the relevant RS Code for the scholarship award i.e. RS977

2) In section ‘Research’ you will see ‘Proposed project title/studentship title’* (Mandatory)

• In ‘Proposed project title/studentship title’ please input:

-         the RS Code, RS977

-         the scholarship title

•                  Please leave Proposed Supervisor field blank

•                  Please leave Research Project (if applicable) blank

•                  In ‘Do you have a proposal to upload? *’(Mandatory) Please select Yes

•                  Then upload copy of advert (you can save the advert by clicking print, and then print to pdf)

3) In section ‘Funding information’ please choose the option ‘Scholarship Funding’ only. Please ensure no other options are selected.

*It is the responsibility of the applicant to list the above information accurately when applying, please note that applications received without the above information listed will not be considered for the scholarship award.

If you’ve previously applied for this programme, the system will display an “Application Submitted” warning and block a new submission. In this case:

1.            Apply for the same course with the next available start date (e.g., select January if October is unavailable).

2.            Email pgrscholarships@swansea.ac.uk with your student number and the relevant scholarship RS code, requesting the start date be amended to match the advert.

3.            Admissions staff will then update your application accordingly.

Important: If you have previously applied for the same programme & intake, do not re‑apply using a different email address. Applications submitted with an email address that differs from the one used in your original application will not be accepted or considered.

One application is required per individual Swansea University led research scholarship award; applications cannot be considered listing multiple Swansea University led research scholarship awards.

NOTE:  Applicants for PhD/EngD/ProfD/EdD - to support our commitment to providing an environment free of discrimination and celebrating diversity at Swansea University you are required to complete an Equality, Diversity and Inclusion (EDI) Monitoring Form in addition to your programme application form.  

Please note that completion of the EDI Monitoring Form is mandatory; your application may not progress if this information is not submitted.

As part of your online application, you MUST upload the following documents (please do not send these via email):

•           CV

•           Degree certificates and transcripts (if you are currently studying for a degree, screenshots of your grades to date are sufficient)

•           A cover letter including a ‘Supplementary Personal Statement’ to explain why the position particularly matches your skills and experience and how you choose to develop the project.

•           One reference (academic or previous employer) on headed paper or using the Swansea University reference form. Please note that we are not able to accept references received citing private email accounts, e.g. Hotmail. Referees should cite their employment email address for verification of reference.

•           Evidence of meeting English Language requirement (if applicable - please note that you do not need to hold a valid English Language test at time of application, as any offer made can be conditional upon the appropriate level of English. Please find further information on what we can accept via our English Language policy pages here).

•           Copy of UK resident visa (if applicable)

•           Confirmation of EDI form submission

Informal enquiries are welcome; please contact:

NAME: Professor Robert Lancaster

EMAIL: r.j.lancaster@swansea.ac.uk

*External Partner Application Data Sharing – Please note that as part of the scholarship application selection process, application data sharing may occur with external partners outside of the University, when joint/co- funding of a scholarship project is applicable.