Development of natural ageing resistant, heat-treatable lean aluminium alloys for automotive applications

About the project

About the Project BCAST is a specialist research centre in metallurgy with a focus on processing of metallic materials for lightweighting applications. See www.brunel.ac.uk/bcast for more information. The project is sponsored by Constellium, a global leading manufacturer of high-quality technically advanced aluminium products and systems. Successful applicants will receive an annual stipend (bursary) starting from approximately £23,000 plus payment of their full-time home tuition fees for a period of up to 48 months (4 years). Lightweight aluminium alloys are essential to modern automotive engineering, enabling improved energy efficiency, reduced emissions, and high manufacturing productivity. Lean aluminium alloys, with reduced levels of alloying elements, offer a practical balance between mechanical performance and processability. However, these alloys are susceptible to natural ageing at room temperature after heat treatment, which can adversely affect formability and limit subsequent strengthening during manufacturing. At the same time, increasing the use of recycled aluminium is a critical challenge for the global aluminium industry as it transitions towards a circular, low-carbon economy. Developing aluminium alloys that combine recyclability, robust processing tolerance, and reliable mechanical performance is therefore of significant scientific and industrial importance. This PhD project will investigate the effects of alloy composition, recycled content, and processing conditions—particularly cooling (quenching) rates—on the natural ageing behaviour and precipitation-hardening response of lean Al–Mg–Si-based alloys. The aim is to design next-generation aluminium alloys that are resistant to undesirable property changes at room temperature, tolerant of industrially realistic processing routes, and suitable for high-productivity automotive applications. The PhD will be conducted within BCAST in partnership with the Constellium University Technology Centre (UTC) at Brunel University London, providing a highly collaborative research environment with joint academic and industrial supervision. The successful candidate will work closely with researchers at BCAST and industrial R&D engineers at Constellium, gaining exposure to both fundamental science and real-world manufacturing challenges. This partnership offers excellent professional development and prepares graduates for careers in industry, research organisations, or academia worldwide. Please contact Prof. Isaac Chang ( Isaac.Chang@brunel.ac.uk ) for an informal discussion about the project. Eligibility Applicants will have or be expected to receive a first or upper-second class honours degree in Materials Science, Mechanical Engineering, Physics, or a similar discipline. A postgraduate master’s degree is not required but may be an advantage. A strong background in physical metallurgy, materials science or chemistry is essential and experience in casting, heat treatment, microstructural characterisation, differential scanning calorimetry and mechanical testing is desirable. In addition, applicants should be highly motivated, able to work independently, as well as in a team and have effective communication skills. How to Apply Please submit your application documents (see list below) in one PDF file by noon on 18 September 2026 to isaac.chang@brunel.ac.uk . • Your up to date CV; • Your personal statement (300 to 500 words) summarising your background, skills and experience; • Your Undergraduate/Postgraduate degree certificate(s) and transcript(s); • Evidence of your English language skills to IELTS 6.5 (or equivalent, 6.0 in all sections), if appropriate; • Contact details for two referees, one of which can be an academic member of staff in the College. Remember to state the title of the project at the top of your personal statement.

Research areas