A representative assessment of novel high performance steels produced through rapid alloy prototyping

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A Rapid Alloy Prototyping (RAP) technique will be employed to develop a high throughput and wide variety of new and innovative materials for Tata Steel UK as part of an EPSRC funded Prosperity Partnership (Tata Steel UK, Swansea University, Warwick Manufacturing Group). This high-throughput approach has the capability of transforming the steel innovation cycle and reducing screening times substantially whilst feeding a diverse supply chain in multiple sectors. The RAP process can generate up to thousands of new miniature-scale materials, with target alloy applications likely covering automotive and tubes for construction and pipeline. In order to down-select and translate these materials into service at full component scale, advanced mechanical testing and characterisation is required. This project aims to investigate the product performance of down-selected alloys in a representative environment by means of carrying out advanced atmospheric testing and simulating in-service loading cycles and conditions. Further properties will also be assessed such as oxidation and corrosion response, Stress Corrosion Cracking susceptibility, fatigue (HCF and LCF) performance, fracture toughness and surface effects. These assessments would typically be carried out utilising standardised test specimens, however, the project will also explore the possibilities of generating similar representative data for miniature and micro-samples and investigating potential scaling and volumetric effects of such tests. If successful, a greater understanding of performance can be obtained without the need to produce large volumes of material. Advanced imaging techniques will be utilised as well as micro in-situ mechanical testing. Material performance will be correlated with process parameters and evaluation of data gathered will be consolidated to further optimise alloy processing. The Research Engineer will:- Define representative service environmental requirements of the laboratory simulation and development of novel testing techniques where required.- Conduct capability validation - benchmarking against existing Tata Steel Alloys, such as Dual Phase Steel 800 (DP800)- Conduct a small-scale investigation: advanced imaging and in-situ testing. Atmospheric and mechanical testing. To understand if sample volume influences data produced. - Undertake full performance assessment and characterisation of down-selected scaled-up materials (chemical. Microstructural, mechanical and environmental).- Understand the effect of microstructure, processing parameters and other properties on materials final performance.- Work in collaboration with Tata Steel partners to optimise selected alloys and processing routes for further scale up to full plant trialsThis project will be in support of the EPSRC Prosperity Partnership. The candidate will have the rare opportunity of being directly involved in the development and optimisation of new, novel steel alloys which provides extensive scope for exploitation via publication and patents. As well as having the ability to develop an advanced, in-depth understanding of materials' performance in a variety of applications, there will also be capacity to explore potential 'blue sky' alloy compositions and novel testing techniques leading to further future developments within the industry.