Digital Engineering of Additive Manufacturing of Advanced Alloys: Material Development and Performance (Ref: FOEU0354AIzt62Cb) at Loughborough University

(Self-Funded/Sponsored Applicants Only)

The Advanced Materials Processing Laboratory (AMPLab) at Loughborough University is seeking an exceptional and motivated PhD candidate (self-funded applicants only) to join our cutting-edge research on 'Digital Engineering of Additive Manufacturing (AM) of Advanced Alloys'. This speculative opportunity is aimed at students with strong interests in metallurgy, computational modelling, and advanced manufacturing, and who wish to shape the future of sustainable and high-performance metal processing.

Project Overview

Additive manufacturing is transforming how we design and build metallic components for critical sectors such as aerospace, energy, nuclear fusion, and space exploration.

However, understanding and digitally controlling the process–structure–property relationships in AM remains one of the biggest scientific challenges in modern materials engineering. This PhD will focus on developing digital frameworks to predict, optimise, and validate the behaviour of advanced metallic systems processed by AM and post- processing routes such as hot isostatic pressing (HIP).

The project will combine computational modelling with experimental validation using cutting-edge facilities available in AMPLab and Loughborough Materials Characterisation Centre (LMCC). You will explore the interplay between powder properties, thermal history, residual stress, and microstructural evolution, and their influence on performance under extreme environments.

Potential Research Themes

Depending on the candidate’s background and interest, the PhD could cover one or more of the following topics:

1. Digital twins of AM and HIP processes: Developing physics-based or data-driven models to simulate powder consolidation, densification, and defect closure during HIPping of alloys such as Ti-6Al-4V, IN718, or V–Cr–Ti for nuclear fusion applications.
2. Alloy design for sustainability: Exploring sustainable and ethical alloy systems, integrating digital design with circular-economy concepts and waste reduction strategies.
3. Performance prediction and qualification: Linking microstructure modelling with mechanical testing, fatigue behaviour, or thermal management performance in components such as tungsten-based plasma-facing parts.
4. Machine learning for materials engineering: Applying AI and digital engineering tools to predict build outcomes, optimise processing windows, and accelerate materials qualification for high-value manufacturing sectors.

Research Environment

You will join a vibrant, multidisciplinary team within the School of Aeronautical, Automotive, Chemical and Materials Engineering, collaborating with industrial and academic partners across the UK and Europe. The group plays a key role in national research programmes on fusion materials, sustainable metallurgy, and advanced manufacturing.

AMPLab and LMCC provides world-class facilities, including metal additive manufacturing systems, mechanical testing rigs, and advanced characterisation tools. You will benefit from close supervision, mentoring, and opportunities to present your work at international conferences.

Join us in redefining the digital and sustainable future of metallic materials.

Name of primary supervisor/CDT lead:

Moataz M. Attallah m.m.attallah@lboro.ac.uk

https://www.lboro.ac.uk/departments/materials/staff/moataz-attallah/

Entry requirements:

Applicants should hold (or expect to hold) a First or Upper Second Class degree (or equivalent) in Materials Science, Mechanical Engineering, Physics, or a related discipline. A strong interest in computational modelling, materials characterisation, or additive manufacturing is desirable. Prior experience with finite element modelling (e.g. COMSOL, ABAQUS, or Ansys), materials processing, or data analysis will be advantageous, but not necessary.

English language requirements:

Applicants must meet the minimum English language requirements. Further details are available on the International website (http://www.lboro.ac.uk/international/applicants/english/).

Bench fees required: Yes

Bench fee value: To be confirmed

Closing date of advert: 31st May 2026

Start date: January 2026, April 2026, July 2026

Full-time/part-time availability: Full-time 3 years

Fee band: 2025/26 Band RB (UK £5,006, International £28,600)

How to apply:

• Stage 1: You are strongly advised to contact Professor Moataz Attallah in the first instance on m.m.attallah@lboro.ac.uk with a CV, academic transcripts, a reference letter, and confirmation of funding source. Informal discussions are also welcome.
• Stage 2: Following discussion with Professor Moataz Attallah, applicants will be invited to make a formal application at online. Under programme name, select ‘Materials’ and quote the advert reference number FOEU0354AIzt62Cb in your application

Project search terms:

engineering, manufacturing engineering, materials science, metallurgy, additive manufacturing

Email Address AACME:

aacme.pgr@mailbox.lboro.ac.uk