3D Temperature Field Reconstruction from Local Temperature Monitoring in Directed Energy Deposition PhD

Cranfield University

We are seeking a highly motivated candidate to undertake a PhD program titled "3D Temperature Field Reconstruction from Local Temperature Monitoring in Directed Energy Deposition." This exciting research opportunity focuses on advancing large-scale additive manufacturing using metal wire as feedstock and electric arc as the heat source. The project aims to develop an innovative and efficient method for reconstructing full 3D temperature fields from partial temperature measurements, utilising monitoring techniques deployable in industrial settings. This work will provide critical thermal insights for diagnosing and controlling defects and lay the foundation for a thermal physics-based approach to process qualification.

Additive manufacturing (AM) is a rapidly evolving technology that continues to drive innovation and find diverse applications across industries such as aerospace, energy, and automotive. Among its various techniques, wire-arc directed energy deposition (WA-DED) stands out as a highly promising approach for fabricating large-scale structural components. This process involves feeding a metal filler wire-either coaxially or off-axis-into an electric arc to generate a molten pool that solidifies on a substrate, enabling the layer-by-layer construction of complex 3D objects. The temperature field created by the interaction between the electric arc and the material is a critical factor influencing the microstructure, residual stress, and distortion of the deposited parts, all of which significantly impact their mechanical properties and overall performance. Consequently, accurately determining and effectively controlling the temperature field are essential to achieving a high-quality WA-DED process.