Inspection of ceramic-based materials used in demanding environments using data-driven systems at Imperial College London

The long-term performance of energy generation (e.g., nuclear plants) and transport applications (e.g., aviation) is underpinned by ceramic-based coatings and composites that can withstand demanding environments. For instance, thermal barrier coatings (TBCs), environmental barrier coatings (EBCs), and ceramic matrix composites (CMCs) are examples of ceramics which can continue to improve product performance and promote sustainability in the aero-engine industry. Given the harsh conditions, these materials may experience degradation through-life driven by complex combinations of thermal, mechanical, and chemical processes, often accelerated by contaminants such as CMAS (calcium–magnesium–alumino–silicates).

Rolls-Royce has identified Raman spectroscopy as a promising technology for non-destructive and potentially on-wing (without dismounting the aero-engine) inspection of such materials. However, the Raman spectra collected in-service are highly complex, and their interpretation requires new approaches that integrate databases of lab-based characterisation data and data-driven analysis protocols. The key challenge is linking spectral features to specific degradation mechanisms and relate these to the environmental degradation of the component. Moreover, a holistic view of the degradation of the material will require to link these degradation mechanisms to other sources of inspection data (e.g. advanced microscopy techniques or visual inspection).

This project will create a data-rich experimental and analytical framework to overcome these challenges. It will combine the following:

• Controlled laboratory experiments that simulate degradation mechanisms in ceramics, generating reference datasets of Raman spectra across different conditions (temperature, stresses, and contaminant exposure).
• Complementary nanoscale characterisation data (e.g., electron microscopy) to validate the key spectral signatures.
• Advanced data-analysis protocols to link lab data to real applications. Methods such as spectral decomposition, machine learning, and database-driven comparison will be applied to extract characteristic features from the Raman datasets. The goal is to create a systematic approach for data-informed inspection, in which spectra are not simply recorded but actively interpreted against a material database.

Rolls-Royce will provide real aero-engine samples to validate our laboratory-generated databases and analysis protocols. Hence, the outputs of the project will directly support the implementation of in-situ/on-wing inspection tools by Rolls-Royce, reducing reliance on destructive testing, enabling predictive maintenance strategies and extending the lifetime of components.

Although the scope of the project is aimed solely at the aero-engine industry, it is possible that the techniques and protocols developed within this project will expand beyond this remit. The testing methodologies and data analysis protocols developed will be relevant for any sector in which ceramics are exposed to complex extreme environments and require careful inspection routines. For instance, we envisage that nuclear energy, where ceramic composites are likely to play a critical role in future fusion and fission reactors, is one example of this. In summary, this project will deliver both fundamental scientific insights into ceramic degradation mechanisms and practical data-informed frameworks and databases for inspection of materials.

Funding Notes

This is a fully-funded project, part of cohort 3 of the EPSRC CDT in Developing National Capabilities in Materials 4.0. The studentship covers fees (home & international), a tax-free stipend of at least £20,780 plus London allowance if applicable, and a research training support grant. 

Candidates of all nationalities are welcome to apply; up to 30% of studentships across the CDT can be awarded to outstanding international applicants. We strongly encourage interested overseas candidates to apply as early as possible.

Enquiries

For general enquiries, please contact doctoral-training@royce.ac.uk.

For application-related queries, please contact a.neri14@imperial.ac.uk.

If you have specific technical or scientific queries about this PhD, we encourage you to contact the lead Oriol Gavalda Diaz (o.gavalda-diaz@imperial.ac.uk).

Application Process

Please note that each partner of the CDT in Materials 4.0 will have its own application process. Applications to CDT projects will have two stages: the local application form (link below) and the standard questionnaire which applicants will need to complete by the application deadline and send to the email address for application-related queries, above.

The Materials 4.0 CDT is committed to Equality, Diversity and Inclusion. We strongly encourage applications from underrepresented groups.

Application Web Page

https://myimperial.powerappsportals.com/  

Click on 'Make a new application', and then type 'Materials 4.0' in the search box.