[School of Natural Sciences PhD Scholarships] Microstructural Engineering of High-performance Recycled Aluminium Alloys through Multi-Scale Characterisation

About the project

About the Project Recycling aluminium requires only around 5% of the energy needed for primary aluminium production, making it a key engineering material for reducing carbon emissions and improving sustainability across the component life cycle. While aluminium offers substantial recycling benefits, the main challenge in aluminium recycling is mitigating the detrimental effects of brittle Fe-rich intermetallic compounds (IMCs) on alloy performance. The conventional strategy to mitigate this adverse effect relies on reducing Fe levels from various recycling steps, which proved to have limited success. Through collaboration with a UK university and industry partner, we have utilised in situ synchrotron X-ray computed tomography (XCT) and digital image correlation (DIC) to investigate the role of Fe-rich IMCs in damage formation in 100% recycled aluminium alloys. This pioneering work highlighted a new pathway for addressing the challenge of persistent Fe impurities in recycled aluminium alloys by enhancing damage tolerance through thermomechanical processing. Furthermore, the processing of recycled aluminium sheet often involves complexed deformation paths, including biaxial loading and bending. However, the mechanisms by which IMCs interact with the surrounding matrix under these complex loading conditions remain poorly understood and requires further investigation. Motivated by these knowledge gaps, this PhD project is designed around two main objectives: (1) To optimise the matrix microstructure of a 100% recycled aluminium alloy containing a given level of Fe impurity through different heat treatment routes, and to establish the relationships between microstructural evolution, strength, ductility and damage tolerance. (2) To systematically correlate heat treatments routes with representative plastic deformation loading paths, thereby establishing a mechanistic framework for the design of high-performance recycled aluminium alloys for demanding engineering applications. To achieve these objectives, the PhD student will use thermodynamic modelling to predict the formation of Fe-rich IMCs during different heat treatments. Mechanical testing will then be performed to establish the links between heat treatment, microstructure, and formability. Finally, advanced in situ XCT and DIC techniques will be employed to investigate the role of Fe-rich IMCs in strain localisation, damage initiation, and failure during deformation. The PhD student will receive bespoke recycled aluminium alloys in the as-cast condition. The supervisory team, together with industrial collaborators, will provide scientific guidance and help shape the research direction throughout the project. The Manufacturing Laboratory within the Department of Materials, as well as the Henry Royce Institute facilities, will provide access to state-of-the-art thermomechanical processing and heat-treatment equipment. Training in advanced characterisation techniques will be provided through the Materials Imaging and Characterisation research theme, enabling the student to develop expertise in X-ray computed tomography and electron microscopy. In addition, the Centre for Light Alloys Research and Innovation, led by Professor Joseph Robson, will provide a broader research environment, facilitating collaboration, knowledge exchange, and access to world-leading expertise in aluminium alloy development and characterisation. Through this comprehensive support network, the student will acquire a diverse range of skills spanning alloy processing, mechanical testing, advanced characterisation, and data analysis, providing a strong foundation for a future career in either academia or industry. This project is expected to start in September 2027. Before you apply: We strongly recommend that you contact the supervisors for this project before you apply. How to apply: To be considered for this project you must complete a formal application through our online application portal. If you already have an applicant account this link will directly open an application for PhD School of Natural Sciences Scholarships . If you don’t already have an applicant account, please follow the instructions here . When applying, please specify the full title and supervisor/s of the project, details of your previous study, and names and contact details of two referees. You must also upload a Supporting Statement describing your motivation to apply to the project, your CV and transcripts of awarded and in-progress university qualifications . Please note late or incomplete applications will not be considered. Equality, diversity and inclusion are fundamental to the success of The University of Manchester and central to all our activities. A diverse research community strengthens creativity, productivity and quality, while increasing the societal and economic impact of our work. We welcome applicants from all career paths, backgrounds and sections of the community, regardless of age, disability, ethnicity, gender, gender expression, sexual orientation or transgender status. We welcome applications from candidates returning to study after a career break or experience in other roles. Flexible study arrangements may be available, including part-time study at 50%, 60% or 80%, subject to the requirements of the project and funder. Eligibility : The standard academic entry requirement for this PhD is an upper second-class (2:1) honours degree (or international equivalent) in Materials Science, Materials Processing, Mechanical Engineering or Physics OR any upper-second class (2:1) honours degree and a Master’s degree at merit (or international equivalent) in Materials Science, Materials Processing, Mechanical Engineering, or Physics. This project will remain open until filled. If your application is submitted by 1 st November 2026, you can expect a decision by 18 th December 2026. If your application is submitted by 15 th January 2027, you can expect a decision by 30 th March 2027. Self or externally funded students can also be considered for this project. FSESoNS

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