Fusion based additive manufacturing or 3D printing of metallic alloys can create complex designs and geometries rendering the built parts suitable for a myriad of applications. Specifically, metal 3D printing is deemed extremely beneficial in biomedical applications where patient-specific customization is possible. In this regard, maraging steels alloys are ultra-high-strength, low-carbon iron-nickel alloys known for superior toughness, weldability, and dimensional stability during heat treatment. They are primarily used in critical aerospace, defense, and high-performance engineering applications. However, additively manufactured alloys
pose certain limitations such as porosities and defects in as-built parts due to the solidification microstructures. To fully understand the additively manufactured maraging steels and leverage the design flexibility with AM, we propose to test solid and lattice geometries of AM maraging steels alongside traditional steels and contrast them in terms of their processing, structure and properties. detailed microstructural characterization will be performed to understand the complicated processing history during metal 3D printing and ascertain the properties. For the microstructural characterization, the student will use
world-class microscopy facilities such as Field Emission Scanning Electron Microscope and X-ray diffractometer at CAMTEC. Additionally, the steels will be tested for their mechanical properties such as strength and elastic modulus to achieve a comprehensive understanding and potential of the materials. A detailed structure-property correlation will allow understanding the effect of microstructural heterogeneity on the observed mechanical anisotropy and other properties.
Research area, student roles & skills
Research area: My research program focuses on coupling advanced technologies such as additive manufacturing (3D Printing) with next-generation metallic materials for structural and functional applications. These advanced materials have applications in aerospace, automobile, biomedical, and electronic sectors. Areas of my current research interest are:
- Design and development of novel alloys and techniques for additive manufacturing
- Unravelling the complex microstructures in additively manufactured alloys
- Microstructure and crystallographic texture control during additive manufacturing
- Multi-scale mechanical behavior of metallic materials (HCP, FCC, and BCC crystal structures)
- Experimental investigations of processing- structure- property- performance relationships
Student roles: The student is required to perform the following duties: • Undergo safety related training and take lab tours to acclimatize at University of Victoria (0.5 week) • Work hands-on on the Universal testing system MTI 10kN to perform mechanical testing (tensile, hardness and compression) of the alloys (2 weeks). • Perform polishing, grinding, and etching of the steel samples, and use the optical microscope to compute the phase fraction and grain sizes of materials (2.5 weeks). • Work on the advanced microscopic facilities at CAMTEC to study the microstructure of the alloys (2 weeks). • Analyze the microstructure and property data to understand the role of microstructure on the mechanical anisotropy (3 weeks). • Writing a technical report that can be converted to/facilitate preparation of a manuscript for a journal/conference publication (2 weeks). In case of a future journal publication of this work, the student will be credited as an author (position in the list of authors depends on the extent of contribution made by the student).
Skills required: • Background in Metallurgical/Mechanical/Industrial Engineering • Having taken materials science related courses and dealt with metallic samples is a strong asset. • Demonstrated experience with using and understanding metallography equipment such as grinding and polishing systems is a plus. • Hands-on experience with mechanical testing is a strong asset • Excellent interpersonal and communication skills, both written and oral. • Ability to use/ learn to use the laboratory equipment independently. • Experience with ImageJ and other image analysis software for optical microscopes is a plus.
2. Additive manufacturing of copper alloys for marine applications
Supervisor: Mohsen Mohammadi
University: University of New Brunswick (Fredericton campus)
The candidate will work on the 3D printing of pure copper and copper alloys using state-of-the-art metal additive manufacturing machines available in the marine additive manufacturing centre of excellence. Using advanced electron microscopy techniques available at the centre, porosity, grain size, phases, and texture of the printed samples are identified. After the initial stage, process parameters will be modified to be able to print copper alloys near to fully dense characteristics.
Research area, student roles & skills
Research area: The main areas of research of Dr. Mohammadi are “Marine Additive Manufacturing” and “Hybrid Additive Repair”. Dr. Mohammadi has published more than 200 journal articles and conference papers in the field and has been appointed as the Canada Research Chair in Marine Additive Manufacturing. Dr. Mohammadi is leading significant projects on metal additive manufacturing in collaboration with marine, defence, energy, and aerospace sectors in Canada and around the globe. He is currently exploring the characteristics of 3D printed alloys for Arctic and Antarctic environments.
Student roles: The student will help with handling metal powder, preparing samples after 3D printing, surface studies, electron microscopy, data analysis, and modelling.
Skills required: Additive manufacturing Finite element modelling Electron microscopy Metal polishing and preparation
3. Co-valorization of critical and strategic elements/Co-valorisation des éléments critiques et stratégiques
Critical and strategic metals such as cobalt, nickel, copper and indium, although highly sought-after, currently pass through the processes of several mineral and metallurgical plants without being valorized. The proposed project will examine, in the first part, the study of mineralurgical processes (flotation, magnetic or gravimetric separation) making it possible to concentrate these elements from existing plant streams to economically produce concentrates. A second part of the work here aims to find ways, once these elements are concentrated, to extract them from carrier minerals and then to obtain saleable products in a cost-effective and environmentally responsible manner. Methods to be studied for this purpose may include selective leaching (including bioleaching) as well as solvent extraction, selective precipitate, resin extraction or electrometallurgy. The project is intended to be applied and will use real samples taken from existing processing plants, giving the workshop an unparalleled realism. Also, the selected intern(s) will support the work of graduate students (doctoral students) already conducting work on this issue.
Research area, student roles & skills
Research area: Our research group is interested in the development of processes related to critical and strategic metals. Mineral processing (grinding, flotation and other separation methods) as well as extractive metallurgy (hydrometallurgy, electrometallurgy and pyrometallurgy) are important axes. In all these areas, we favor an experimental approach with state-of-the-art equipment in order to promote a good understanding of the processes allowing their modeling and simulation. Economic analysis and sustainable development in connection with these processes are other prime targets of the group's work.
Student roles: It is expected that the intern will be able to perform a variety of clerical and/or laboratory tasks. These tasks may include: - Compiling literature and writing reading notes on the topic; - Planning and carrying out laboratory work that may involve various processes related to asbestos recovery, such as mineral separation, leaching and purification of solutions. Bioprocesses could be one of the options considered. - Drafting procedures and technical reports reporting on laboratory work, including material balances.
Skills required: The candidate should be familiar with concepts related to minerals (mineralogy) materials (thermodynamics and advanced characterization) and processes (material balances, yield calculations, reaction kinetics and reactor sizing). The ability to work in a laboratory, and to read in English are vital. Great curiosity and good interpersonal skills will be assets!
4. Mass and energy balances in arc welding
Supervisor: Patricio Mendez
University: University of Alberta (Edmonton campus)
This project will involve analyzing the relationship between welding power and weld material deposited; it will also involve understanding the source and amount of metal vaporized due to the heat of welding. This project is of much relevance to the designers of welding equipment because the performance of their equipment is affected by unknown reasons, and unexpected adjustments must be done by trial and error for each particular application. The flow of energy also causes evaporation of metal, which turns into welding fumes (nanoscopic particles floating in the air) which can have severe health and legal consequences, sometimes preventing certain tasks because of legal or economic considerations. This project might involve an experimental component aimed to determine some unknown parameters associated with the welding plasma.
Research area, student roles & skills
Research area: The Canadian Centre for Welding and Joining (CCWJ) has several areas of specialization, including: laser cladding, plasmas, heat transfer in manufacturing, welding physics, materials processing, metallurgy, mathematical modeling, welding.
Student roles: The potential impact of this project is very high because of the large demand from industry for practical solutions based on the proper physics. For the experimental testing, student must be proficient in a laboratory experiment, respectful of safety guidelines. Must be familiar and skilled with basic hardware tools. Skills in Python or LabView will be very welcome. For experiments, the student can (if desired) operate equipment and high-speed video, process and edit video and data acquisition signals.
Skills required: Student must be able to concentrate on the problem and make intellectual contributions. Student will learn state of the art approaches to modeling heat and mass transfer in welding with the help and mentorship of faculty and graduate students. After learning fundamentals, student will reproduce existing models, and then will extend models into novel situations. Students must also be able to learn basic scientific software such as ThermoCalc or JMatPro. Good command of Matlab or Excel will be especially strong assets.
5. Physics of Thermal Plasmas at Atmospheric Pressure
Supervisor: Patricio Mendez
University: University of Alberta (Edmonton campus)
The ultimate goal of this work is to predict the properties of thermal plasmas at atmospheric pressure. This type of plasmas are crucial for technological applications such as welding, circuit breakers, cutting tools, and more. Despite their importance, they currently cannot be treated with engineering tools such as formulae or tabulated data.
This project will focus on modeling the coupled physics in the welding arc, with a focus on providing a general quantitative set of formulas and tabulated data useful both in research and industry. Such work will generalize current data that is currently unconnected and of little use in industry or research. This work will benefit much from current collaborations with the Department of Physics and projects with partner companies.
In this project students will learn the theory behind these plasmas, and become familiar with foundational and current literature on thermal plasmas. Students will also have direct access to thermal plasmas produced at currents up to 1000 A and to high-quality plasma spectrometry equipment.
A very high impact is expected from this work, as it will be the first time the arc and the influence of different gases are properly considered in a general way, amenable to industrial implementation in the form of simple formulae for the engineers, and tables and graphs for the practitioners.
Research area, student roles & skills
Research area: The Canadian Centre for Welding and Joining (CCWJ) has several areas of specialization, including: laser cladding, plasmas, heat transfer in manufacturing, welding physics, materials processing, metallurgy, mathematical modeling, welding.
Student roles: In this project students will learn the theory behind these plasmas, and become familiar with foundational and current literature on thermal plasmas. Students will also have direct access to thermal plasmas produced at currents up to 1000 A and to high-quality plasma spectrometry equipment.
Skills required: Required skills for this project include having passed an introduction to fluid mechanics, introduction to heat transfer, introduction to electromagnetism, basic use of Microsoft Excel, self-motivation, natural curiosity, patience, and ability to act on feedback from the supervisor. Desirable skills for this project include the ability to write code (e.g. Matlab), and previous experience on heat transfer, fluid flow, or plasmas.