Material degradation study of heat-exchanger materials and coatings for renewable energy PhD Self-funded PhD opportunity

This is a self-funded PhD position to work with Dr Adnan Syed in the Surface Engineering and Precision Centre. The PhD project will focus on studying high temperature corrosion mechanisms in detail to identify material degradation and coatings application details in extreme environments. A novel technique/method will be developed with focus on better prediction and more accurate measurement of high temperature corrosion rate involving mathematical models validated through simulation, experiments and analysis.

Post COP26, the UK has set a target to cut emissions of greenhouse gases to net zero by 2050. The power generation sector considers agricultural waste as a renewable energy source which can help offset coal combustion. Such Waste to Energy (WtE) plants produce flue gases that can have much higher levels of SOX and HCl than coal fired systems, and this can cause increased high temperature corrosion (HTC) damage to surfaces of heat-exchanger (HX) materials. Coating of HX materials in power plant boilers is widely used to mitigate HTC. Multiple routes for coating chemistry and application processes are being considered. A novel approach of multi-layered advanced material coatings system will be studied in this project. The lack of ability for early detection and timely prevention of high temperature corrosion has resulted in many HX failures leading to long term maintenance and replacement of parts.

The alloy material of HX is prone to high temperature corrosion attack because of the corrosive nature of molten salt deposits and gases. The salt deposits and their direct contact with alloy material at elevated temperatures cause high-temperature corrosion.

You will investigate various alloy types and corrosion testing methods to determine a suitable alloy and coating system. The project includes a detailed literature survey leading to the development of a test matrix, including test conditions and types of alloys used (bare or coated). The project includes testing the material in the facility available at Cranfield's high temperature corrosion laboratory. A detailed analytical phase for better understanding of the microstructure requires working with advanced microscopy tools such as SEM/EDX, FIB and TEM. Dimensional metrology for metal loss evaluation will also be used. Thermodynamics calculations using FactSage software will be employed, along with electrochemical characterisation techniques using online electrochemistry to interpret corrosion rates.

You will be based at the Surface Engineering and Manufacturing Centre, which provides state-of-the-art equipment for the testing, analysis and characterisation of materials. The Centre holds a network with the aerospace and energy sector, providing the possibility of meetings with relevant industrial clients for networking and technical guidance.

Research carried out during this PhD project will lead to better understanding of Fireside corrosion that will eventually:
- Enable early failure identification.
- Enable material selection criteria for alloys and coatings systems.
- Increase alloys and coating material knowledge of performance in extreme environments.
- Improve HX material outcome.

Although the research proposed here will focus on HX, by changing the testing conditions, the technology developed here could be easily adapted for aerospace and other power generation applications.

You will work in a multidisciplinary environment consisting of material scientists, chemists, engineers and physicists. During the PhD, the candidate will gain invaluable experience working at the intersection of several research fields. This self-funded PhD project includes the ability to participate in industry-led research initiatives and access to the Cranfield Doctoral Training Network.

You will gain knowledge of high temperature materials applications for the energy and aerospace sectors, knowledge of alloy material behaviour in aggressive conditions, micro-level analysis of material structure at the atomic level, and skills in presenting results at conferences and meetings.

At the end of the PhD, you will have become a well-rounded independent scientist with the possibility to progress your career either in academia or industry across material science and engineering, energy and aerospace.

Entry Requirements: Candidates should have a minimum of an upper second (2:1) honours degree (or equivalent) preferably in one of the following disciplines: Chemistry, Material Science, Physics, Mechanical Engineering or related fields. Candidates with an MSc degree in these disciplines will be desirable.

Funding: Self-funded. Open to UK, EU and international applicants.

Duration: 3 years.