Advanced manufacturing encompasses the wide range of processes that consist of ‘3D printing’ of metallic materials. This can include such powder bed methods as Electron Beam Melting (EBM) and Direct Laser Deposition (DLD), two modern build technologies that offer significant potential for lean manufacture and a capability to produce near-net shaped final components. A key limitation of these techniques is microstructural control in relation to a number of key process variables. For instance the manufacture of intricate geometries will result in variable thermal cycles and thus a transient microstructure throughout, leading to a highly textured structure. As such, successful implementation of these technologies requires a comprehensive assessment of the relationships of the key process variables, geometries, resultant microstructures and mechanical properties. The nature of these processes suggest that it is often difficult to produce representative test specimens in order to achieve a full mechanical property characterisation. Therefore, the use of small scale test techniques may be exploited, specifically the small punch (SP) test. The SP test offers a capability for sampling miniaturised test specimens from various discrete locations, allowing a full characterisation across a complex component. In addition, SP results may be tentatively correlated to more conventional test approaches. Ongoing research aims to provide support in working towards development and validation strategies in order for advanced manufactured components to be safely implemented in future gas turbine applications. This research is funded by EPSRC and Rolls-Royce as part of the Strategic Partnership in Structural Materials.

Areas of Expertise

  • Miniaturised Testing
  • Additive Layer Manufacturing (ALM) processes
  • Nickel Superalloys (single crystals, polycrystalline)
  • Thermo-mechanical Fatigue
  • Fatigue Lifing
  • Failure Analysis
  • Non-Destructive Evaluation
  • Titanium Alloys

Publications

  1. Hilal, H., Lancaster, R., Jeffs, S., Boswell, J., Stapleton, D., Baxter, G. The Influence of Process Parameters and Build Orientation on the Creep Behaviour of a Laser Powder Bed Fused Ni-based Superalloy for Aerospace Applications Materials 12 9 1390
  2. Lewis, D., Lancaster, R., Jeffs, S., Illsley, H., Davies, S., Baxter, G., Lancaster, R., Jeffs, S. Characterising the fatigue performance of additive materials using the small punch test Materials Science and Engineering: A
  3. Smith, R., Lancaster, R., Jones, J., Mason-Flucke, J. Lifing the Effects of Crystallographic Orientation on the Thermo-Mechanical Fatigue Behaviour of a Single-Crystal Superalloy Materials 12 6 998
  4. Lancaster, R., Jeffs, S., Illsley, H., Argyrakis, C., Hurst, R., Baxter, G., Lancaster, R., Jeffs, S. Development of a Novel Methodology to Study Fatigue Properties using the Small Punch Test Materials Science and Engineering: A 748 21 29
  5. Palmer, J., Jones, J., Dyer, A., Smith, R., Lancaster, R., Whittaker, M., Whittaker, M., Lancaster, R. Development of test facilities for thermo-mechanical fatigue testing International Journal of Fatigue 121 208 218

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Teaching

  • EG-110 Engineering Skills & Applications

    Competence in Engineering Drawing and its standards using an industry standard CAD system and essential laboratory skills for Mechanical Engineers.

  • EG-163 Design and Laboratory Classes 1

    Competence in engineering drawing using an industry standard CAD system and essential laboratory skills

  • EG-287 Materials Practicals 2b: Applied examples in advanced metallic materials

    Materials Practicals 2b: Applied examples in advanced metallic materials - identification and assessment of microstructures and mechanical properties of a variety of ferrous and non-ferrous alloys. The module will explore the link between microstructure and mechanical properties and show how processing treatments can radically alter the microstructure and behaviour of materials.

  • EGTM76 Professional Development for Engineers

    Professional skills can be defined as the transferable skills needed by an individual to make them `employable¿. Along with good technical understanding and subject knowledge, employers often outline a set of skills that they desire from an employee. These skills are what they believe will equip the employee to carry out their role to the best of their ability. Employability depends on your knowledge, skills and attitudes, how you use those assets, and how you present them to employers. This module will introduce a range of professional skills, the importance of them and how they can be developed and enable the student to assess his/her own weaknesses and strengths in terms of individual and team working environments.

Supervision

  • Materials and Mechanical Characterisation of Additive Manufactured Alloys for the Nuclear Sector (current)

    Student name:
    EngD
    Other supervisor: Dr Helen Davies
  • Damage tolerance study of F1E (current)

    Student name:
    EngD
    Other supervisor: Prof Mark Whittaker
  • Untitled (current)

    Student name:
    PhD
    Other supervisor: Dr Spencer Jeffs
  • Small scale testing of high `y` nickel based superalloys manufactured by ALM (current)

    Student name:
    EngD
    Other supervisor: Dr Helen Davies
  • Quantifying deformation in high temperature materials using digital image correlation (DIC) (current)

    Student name:
    EngD
    Other supervisor: Dr Soran Birosca
  • Optimisation of the thermomechanical processing of Inconel 718 (current)

    Student name:
    MSc
    Other supervisor: Prof Mark Whittaker
  • The Development of Isolated Nickel Alloy Products & Thermomechanical Process Routes at Doncasters Blaenavon (current)

    Student name:
    MSc
    Other supervisor: Prof Mark Whittaker
  • Understanding the Effect of Surface Finish on the Fatigue Performance of Additive Manufactured Aerospace Components (current)

    Student name:
    EngD
    Other supervisor: Prof Richard Johnston
  • Corrosion of F1E Study. (current)

    Student name:
    EngD
    Other supervisor: Dr Spencer Jeffs
  • Untitled (current)

    Student name:
    PhD
    Other supervisor: Prof Mark Whittaker
  • Untitled (current)

    Student name:
    PhD
    Other supervisor: Prof Mark Whittaker
  • Environmentally induced damage propagation with localised stresses in CMCs (current)

    Student name:
    PhD
    Other supervisor: Dr Spencer Jeffs
  • Untitled (current)

    Student name:
    PhD
    Other supervisor: Dr Spencer Jeffs
  • The investigation of the mechanical and microscopic evolution of additive manufactured aerospace components. (current)

    Student name:
    PhD
    Other supervisor: Prof Richard Johnston
  • Aerofoil testing and microstructures of high integrity material addition repairs in titanium alloys. (current)

    Student name:
    PhD
    Other supervisor: Prof Mark Whittaker
  • Improved Melt pool monitoring systems for laser metal deposition processes (awarded 2019)

    Student name:
    PhD
    Other supervisor: Prof Geraint Williams
  • Optimising the thermo-mechanical processing of haynes 282 forging (awarded 2019)

    Student name:
    MSc
    Other supervisor: Prof Mark Whittaker
  • Small scale testing of an additive manufactured AerospaceTitanium Alloy (awarded 2019)

    Student name:
    EngD
    Other supervisor: Prof David Worsley
  • Microstructure-Mechanical property relationships of electron beam melted Ti-6Al-4v (awarded 2019)

    Student name:
    EngD
    Other supervisor: Prof David Worsley
  • Microstructure-Mechanical property relationships in powder bed laser deposits (awarded 2019)

    Student name:
    EngD
    Other supervisor: Prof David Worsley
  • High Temperature Thermo Mechanical Faitigue Behaviour of Single Crystal Nickel Based SuperAlloy CMSX-4 (awarded 2018)

    Student name:
    PhD
    Other supervisor: Prof David Worsley

Career History

Start Date End Date Position Held Location
2015 Present Senior Lecturer Materials Research Centre, Swansea University
2013 2015 Institute of Structural Materials (ISM) Lecturer Materials Research Centre, Swansea University
2012 2013 Senior Research Officer Materials Research Centre, Swansea University
2011 2012 Senior Project Leader Non-Destructive Validation Centre, TWI
2007 2011 Research Officer Materials Research Centre, Swansea University

Key Grants and Projects

  • Horizon 2020 Framework programme – ‘DevTMF’ (Development of Experimental Techniques and Predictive Tools to Characterise Thermo-Mechanical Fatigue Behaviour and Damage Mechanisms) 2015

    , £704,061

  • National Research Network (NRN) – PhD studentship funding to assess the application of Non-Destructive Test Methods to Advanced Manufactured Components 2015 0

    , £60,000

  • EPSRC/Rolls-Royce – Strategic Partnership in Structural Metallic Systems for Advanced Gas Turbine Applications Core Research 2014

    , £25,000,000

  • National Research Network (NRN) – PhD studentship funding to investigate the effect of TMF on single crystal materials 2014

    , £60,000

  • EPSRC/Rolls-Royce – Strategic Partnership EngD 2014

    , £120,000

  • NSA Welsh Government – Materials Live, a Welsh National Science Academy project designed to increase the awareness of the subject to children of all ages 2013

    , Total Project value = £160k

  • EPSRC/Rolls-Royce – Strategic Partnership EngD 2013

    , £120,000

  • Successful research proposals to EPSRC for specialist thermal imaging equipment 2012

    , £10,000

External Responsibilities

  • Guest Editor, Materials special edition – “Failure Analysis in Materials”

    2015 - Present

  • Secretary, IOM3 Structure & Properties of Materials Committee

    2014 - Present

  • Member, BSi ISE/101/01 Uniaxial Testing committee

    2016 - Present

  • Scrutineer, Engineering Chartership Applications on behalf of IOM3

    2015 - Present

  • Professional Member, IOM3 (MIMMM)

    2015 - Present

  • Fellow, Higher Education Academy (FHEA)

    2016 - Present

  • Reviewer, 7 International Journals including Materials & Design

    2008 - Present

  • External Examiner, PhD/EngD examinations at Birmingham University

    2015 - Present

Awards And Prizes

Date Description
2015 Awarded Chartered Engineer status
2004 Armourers & Brasiers Medal and Prize (Overall excellence in metallurgy)
2004 Worshipful Company of Tinplate Workers (Best results in metallurgy exams)

Academic History

Date Qualification Location
2016 Postgraduate Certificate in Teaching in Higher Education (PGCtHE)

Administrative Responsibilities

  • Materials Research Centre representative - College of Engineering’s Ethics Committee

    2015 - Present