Functionally graded ceramic-metal tools with excellent machining performance

The Machining Group of the mechanical department focuses on the investigation, development and implementation of non-conventional and hybrid processes for the machining of advanced materials and complex shaped components, post processing of additive manufactured parts and up-coming needs such as the machining of functional surfaces.
The research activities of the “Advanced Ceramics and Powder Metallurgy” research group of the Department of Materials Engineering focus on powder based materials, i.e., ceramics, powder metallurgical alloys and their composites. The main research topics are powder synthesis and shaping techniques, advanced sintering technologies, structural/functional properties and modelling of the processing and the behavior of powder based materials. We aim to develop high-quality structural/functional ceramics and powder metallurgical products, based on a basic understanding of the powder based materials processing
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Project

The current vacancy offers a 48-monthPhD position focusing on the development of functionally gradient Ceramic-Metal materials (WC-Co, TiCN-Ni etc.) for tooling applications. The topic aims to development tools with excellent machining performance, combining both the advantage of cemented carbide and cermet. This ambitious topic is within the larger project of Near-Net Shape Manufacturing of Innovative Multi-Materials. Multi-materials fabrication has always been a major challenge for the powder metallurgy industry, especially when geometrically-complex parts are targeted, and difficult-to-densify materials or material combinations are envisaged. Extensive and costly hard-machining or green machining, before a final sintering step, requiring a green body with sufficiently high green strength, are required. Additive manufacturing of cemented carbides is quickly growing in the past few years, mostly for its ability to create 3D complex ceramic bodies with good mechanical properties. The current project aims at reducing or even eliminating post machining operations and integrating multiple functionalities within a single, geometrically-complex part by the development of multi-materials and/or functionally graded materials, exhibiting a gradient in composition and/or microstructure. Paste extrusion and post sintering method is one of the techniques available for ceramic additive manufacturing. Of great interest is the possibility to fabricate multi-materials in one single printing step, using multiple pastes indifferent printheads.

     The research plan for the proposed PhD project covers the full powder metallurgy processing chain, microstructural& mechanical characterization, as well as tool performance evaluation in machining (e.g. turning, milling ...). The topic includes the following main tasks:

·        Multi-material system composition design and stress simulation

·        Materials feedstock preparation and printing

·        Sintering behavior study

·        Microstructural and mechanical properties characterization

·        Machining tool performance evaluation, mainly by experimental machining tests.

Profile

- Candidates should have recently obtained a Master’s degree in Materials Science/Engineering, Physics, Chemistry or Electro-Mechanical engineering with outstanding grades.

- Candidates should have a stron gexperimental and theoretical background in at least one of the following topics: Materials processing, Ceramics, Powder metallurgy, Machining.

- Desirable: Ceramic processing, powder metallurgy research experience, machining experience.

- Language skills: English excellent.

- Candidates have to be hard working, enthusiastic and intelligent with a strong interest in understanding the fundamentals of materials behavior and machining, as well as its implications for engineering applications.

- You have a talent for conceiving advanced experimental set-ups and can realize them in a target-oriented manner.

Offer

This vacancy offers a PhD of KU Leuven, an international environment, guidance by leading scientists, competitive fellowship, social security, and other benefits. The candidate will be part ofa team of 3 PhD students, 1 expert, and 3 professors, work withstate-of-the-art equipment, and receive an attractive salary in accordance with the KU Leuven regulations.

• Ample occasions to develop your scientific and personal skills. Besides opportunities offered by the research group, further doctoral training for PhD candidates is provided in the framework of the KU Leuven Arenberg Doctoral School (https://set.kuleuven.be/phd), known for its strong focus on both future scientists and scientifically trained professionals, who will valorise their doctoral expertise and competences in a non-academic context. More information on the training opportunities via https://set.kuleuven.be/phd/dopl/whytraining.
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• A stay in a vibrant environment in the hearth of Europe. The university is located in Leuven, a town of approximately 100000 inhabitants, located close to Brussels (25km), and 20 minutes by train from Brussels International Airport. This strategic positioning and the strong presence of the university, international research centres, and industry, lead to a safe town with high quality of life, welcome to non-Dutch speaking people and with ample opportunities for social and sport activities. The mixture of cultures and research fields are some ofthe ingredients making the university of Leuven the most innovative university in Europe (https://nieuws.kuleuven.be/en/content/2018/ku-leuven-once-again-tops-reuters-ranking-of-europes-most-innovative-universities).Further information can be found on the website of the university: https://www.kuleuven.be/english/living

Interested?

For more information please contact dr.ir. Shuigen Huang, e-mail: Shuigen.huang@kuleuven.be.

Applications must contain:

• An up-to-date CV, detailing workexperience, research and academic achievements.

• Motivation letter.

• At least two reference letters from a(former) supervisor, professor or a manager with contact information.

• Scanned copy of the degree (usually the master’s degree) which would formally entitle the candidate to embark on a doctorate.

• Transcripts (applicant’s ranking and marks) for both Bachelor and Master degree. In case the applicant has notobtained a Master degree yet, a copy of the most up to-date Master grades should be provided.

• A copy of an identity document.

• An English language certificate (IELTSor TOEFL) is needed.

Any document not originally in English must be provided together with an English translation.

KU Leuven seeks to foster an environment where all talents can flourish, regardless of gender, age, cultural background, nationality or impairments. If you have any questions relating to accessibility or support, please contact us at diversiteit.HR@kuleuven.be.