MA (Hons), MSc, PhD, MIMA, Prof Grad IMMM, FHEA

Dr Nicholas Lavery is Director of the Materials Advanced Characterisation Centre (MACH1), and the lead academic of the Swansea Additive Manufacturing Research (SAMR) group.

Dr Lavery's research interests lie broadly in the use of material property measurement, computational modelling and experimental studies to develop novel industrial manufacturing processes and materials, with applications to engineering products in aerospace, medical, automotive and energy production.

Current research areas:

  • Additive Manufacturing (specifically Laser Powder-bed Fusion)
  • High Throughput Material Property Testing (MACH1)
  • Computational modelling of various manufacturing processes (Additive Layer Manufacturing, Extrusion, Isostatic Powder Pressing, Sintering …)
  • Rapid Alloy Prototyping
  • Life Cycle Assessment

Over time spent in academic and industry, I have established a very wide range of international research collaboration demonstrated by the invitation to participate in and develop a number of EC FP7/H2020 proposals.

I am a recognised outstanding reviewer for the Journal of Alloys and Compounds, the Journal of Additive Manufacturing and the Journal of Applied Mathematical Modelling.

I have been an International reviewer for Additive Manufacturing proposals for the Canadian Innovation Foundation and the Singapore Science and Engineering Research Council.

Areas of Expertise

  • Additive Layer Manufacturing
  • High Throughput Materials Characterisation
  • Novel Alloy Development
  • Multi-physics coupled Computational Fluids Dynamics
  • Finite Element Analysis
  • Life cycle assessment
  • computational modelling

Publications

  1. (2017). The influence of powder ageing characteristics on 316l stainless steel processed by laser based powder bed fusion. Presented at Proceedings Euro PM 2017: International Powder Metallurgy Congress and Exhibition, Milan, Italy: International Powder Metallurgy Congress and Exhibition, Euro PM 2017.
  2. & A pragmatic continuum level model for the prediction of the onset of keyholing in laser powder bed fusion. The International Journal of Advanced Manufacturing Technology
  3. Scandium-Based Hexagonal-Closed Packed Multi-Component Alloys. Physics of Metals and Metallography 119(8), 735-740.
  4. & Temperature and time dependent structure of the molten Ni81P19 alloy by neutron diffraction. Journal of Non-Crystalline Solids 500, 359-365.
  5. & The Effect of Scandium Ternary Intergrain Precipitates in Al-Containing High-Entropy Alloys. Entropy 20(7), 488

See more...

Teaching

  • EG-M113 Advanced Manufacturing of Metals

    The module will provide a deeper understanding of the physical principles underlying the processing of near net and net shaped technologies for advanced metal manufacturing. The course will cover casting, semi-solid metal manufacturing (Thixoforming), additive layer manufacturing and Powder Metallurgy for manufacturing. NOTE. Continuous casting methods will not be covered. The areas covered will cross cut the engineering disciplines of advanced manufacturing technology and material science to broaden the technical and industrial context of both conventional and advanced manufacturing for metals.

  • EG-M37 Additive Manufacturing

    1.1 Introduction to Additive Manufacturing 1.3 Additive Manufacturing Processes 1.3 Applications of Additive Manufacturing 1.4 Mechanics of the Powder Bed System 1.5 Physics of Additive Manufacturing 1.6 AM Defects and Process Control 1.7 Measurement and analysis of AM properties 1.8 Computer Aided Engineering of AM Parts 1.9 Powder Metals 1.10 Design for AM and part preparation

  • EGA324 Mechanical Engineering Practice

    The course builds on the knowledge and experience developed by the students in experimental studies during Level 2. A number of advanced scientific experiments will be undertaken. In addition, students will carry out a number of modelling benchmark problems in order to develop their ability to create appropriate models, interpret the predictions and compare them with alternative solutions.

Supervision

  • Modelling and improving the vapour deposition efficiency of a novel PVD-based galvanising process (current)

    Student name:
    EngD
    Other supervisor: Dr David Penney
  • Towards state of the art vacuum locks for a novel continuous PVD galvanising process (current)

    Student name:
    EngD
    Other supervisor: Dr David Penney
  • Advanced Manufacturing Techniques of Implantable Blood Pumps (current)

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

    Student name:
    EngD
    Other supervisor: Prof Steve Brown
  • Computational modelling and validation of thermal and flow aspects of the powder bed fusion process (current)

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

    Student name:
    MPhil
    Other supervisor: Prof Steve Brown
  • An Investigation of Residual Stress in the Laser-Powder Bed Fusion Process (current)

    Student name:
    EngD
    Other supervisor: Prof Johann Sienz
  • Assessing the corrosion performance of additively manufactured 316L steel and other industry relevant materials. (current)

    Student name:
    PhD
    Other supervisor: Prof James Sullivan
  • Pelletisation of ferrous by-products (current)

    Student name:
    EngD
    Other supervisor: Prof Steve Brown
  • "Investigation into Additive Manufacturing for Controlling Thermal Expansion in Optical Applications." (current)

    Student name:
    PhD
    Other supervisor: Prof Steve Brown
  • High throughput methodologies and materials characterisation for the optimisation and discovert of new alloys (current)

    Student name:
    PhD
    Other supervisor: Prof Steve Brown
  • Organic and hybrid printable thermoelectric materials (current)

    Student name:
    PhD
    Other supervisor: Dr Matthew Carnie
  • Numerical Property Prediction of Materials Processed via Powder Bed Fusion Additive Manufacturing (current)

    Student name:
    EngD
    Other supervisor: Prof Steve Brown
  • The Effects of Microstructure and Microtexture Generated during Solidification on Deformation Micromechanism in IN713C Nickel Based Superalloy«br /»«br /»«br /» (current)

    Student name:
    PhD
    Other supervisor: Dr Soran Birosca
  • Using Rapid Alloy Prototyping To Understand The Effects Of Tramp Elements In Increased Scrap Steel Recycling (current)

    Student name:
    EngD
    Other supervisor: Dr Cameron Pleydell-Pearce
  • Wear and Impact analysis using 3D Discrete Element Method simulations (current)

    Student name:
    EngD
    Other supervisor: Prof Steve Brown
  • Computational Modelling and Verification of the ALM Melt Pool (awarded 2018)

    Student name:
    EngD
    Other supervisor: Prof Steve Brown
  • Development of multi-scale and multi-physical models of the ALM process (awarded 2018)

    Student name:
    EngD
    Other supervisor: Prof Steve Brown
  • 'Scandium Metal Processing for Aerospace Application' (awarded 2018)

    Student name:
    PhD
    Other supervisor: Prof Steve Brown

Career History

Start Date End Date Position Held Location
2018 Present Associate Professor College of Engineering, Swansea University
2013 2018 Senior Lecturer Materials Research Centre, Swansea University
2013 Present Director Materials Advanced Characterisation Centre (MACH1), Swansea University
2011 2013 Senior Research Officer College of Engineering (ASTUTE Project), Swansea University
2006 2011 Exploitation Expert/Business Development Manager European Space Agency – The Netherlands
2001 2006 Commerical/Technical Manager (Research Officer) Materials Research Centre (CETIC project), Swansea University
1999 2001 Research Officer Materials Research Centre (DSTL Project), Swansea University
1997 1999 Postdoctoral Research Assistant Applied Mathematics & Engineering Department, University of California, San Diego, USA
1995 1997 Postdoctoral Research Officer Mechanical Engineering Department (EPSRC Project), Swansea University

Academic History

Date Qualification Location
1995 PhD Multigrid finite element incompressible turbulent flow University of Wales, Swansea
1992 MSc Computational Modelling University of Wales, Swansea
1991 MA(Hons) Mathematics University of Cambridge
2018 FHEA Swansea University

Invited Presentations, Lectures and Conferences

Date Description
April 2014 Computational Methodology for Optimal Design of Additive Layer Manufactured Turbine Bracket
April 2014 A Review of Computational Modelling of Additive Layer, Manufacturing - Multi-Scale and Multi-Physics
April 2014 An Experimental and CFD Investigation into the Mixing in a Closed System Stirred Vessel
April 2014 A Methodology for Automated Pellet size Distribution in a Pellet Mill
April 2014 The Development of a Sub-Atmospheric Two-Phase Thermosyphon Natural Gas Preheater using a Lumped Capacitance Model
April 2014 Design for Reliability of Steering Power Module due to Design Consideration and Material Selection
April 2014 Studying Microstructure and Crystallinity of Polypropylene in an Injection Moulded Medical Bin Lid
April 2014 Numerical Modelling of a Marine Vessel Engine Room with Field Measurements
April 2014 Suitability of Multi-Layer Perceptron Neural Network Model for the Prediction of Roll Forces and Motor Powers
April 2015 keynote speaker on Rapid Alloy Prototyping at IMMM Steel Strategy Seminar Series, April 2015, Port Talbot

External Responsibilities

  • Member, Institute of Mathematics and its Applications (IMA)

    2006 - Present

  • Professional Graduate Member, Institute of Minerals, Mining and Materials (IoMMM)

    2006 - Present

  • Treasurer of the Steering Committee, Materials Technology Forum for Wales

    2003 - 2006

  • Member of NPL Industrial Advisory Groups, Heat Transfer in Polymers & Photo-thermal Methods

    2001 - 2006

  • Member, South Wales Metallurgical Association & IT Network Forum

    2001 - 2006

  • Member-of & Conference Chairman, American Society of Mechanical Engineers (ASME)

    2005 - 2006

  • Member, TMS (Metals, Materials and Metallurgical Transactions Society)

    2006 - 2011

Key Grants and Projects

Awards And Prizes

Date Description
August 2017 28th SFF Symposium, Texas USA: The three-prong method: a novel assessment of residual stress in laser powder bed fusion
October 2015 Best poster 8th Int. Conf. on Materials for Advanced Technologies, Materials Research Society, Korea