Fully Funded PhD Studentship: Microstructure and Defect Control in Recycled Aluminium Alloys

Project description The transition to a circular economy requires much greater use of recycled aluminium. However, wider adoption of secondary aluminium alloys remains limited by impurity-related microstructural defects and reduced casting reliability. Among these impurities, iron (Fe) is particularly problematic as it promotes the formation of Fe-rich intermetallic compounds, which can impair castability and reduce performance. At the same time, recycled alloys are often more susceptible to solidification defects during processing. This PhD project will investigate the interplay between grain refinement, Fe impurities and defect susceptibility in recycled aluminium alloys. The overall aim is to establish how microstructure develops under different alloy and processing conditions, and how this influences defect formation during casting and solidification. The project addresses a major challenge in aluminium manufacturing: how to enable greater use of recycled alloys without compromising processability or material performance. The research will combine controlled laboratory-scale experiments with pilot-scale casting trials to bridge fundamental understanding and industrial relevance. The relationships between composition, Fe concentration, and processing parameters will be systematically studied to identify conditions under which microstructure and defect behaviour can be most effectively controlled. The project will be carried out in collaboration with the Norwegian University of Science and Technology (NTNU) and with a leading aluminium producer, providing opportunities for international collaboration and engagement with industrially relevant processing challenges. Training and research environment The successful candidate will join the School of Engineering and Informatics at the University of Sussex, working within a growing research environment in sustainable materials engineering. The project offers opportunities for international collaboration with NTNU, including the possibility of a research secondment where appropriate. The lead supervisor will be Dr Shikang Feng. The student will gain training in alloy processing, microstructural characterisation, solidification science, and advanced imaging techniques, while developing expertise highly relevant to both academia and industry. Candidate requirements This studentship is available to UK and Overseas applicants. Eligible candidates will normally have an upper second-class (2:1) undergraduate honours degree (or equivalent qualification) in a related field. 21,805 per year