Advanced Manufacturing of High-Performance Tungsten Carbide for Demanding Environments

This PhD project will investigate the erosion-corrosion behaviour of tungsten carbide produced using a novel sintering-based additive manufacturing process. The research will combine advanced manufacturing, erosion-corrosion testing, electrochemical monitoring, and materials characterisation, providing multidisciplinary training with strong industrial relevance. <br /> <br /> Key objectives are to:<br /> - Establish the erosion-corrosion performance of conventionally manufactured tungsten carbide in particle-laden corrosive environments.<br /> - Develop and optimise a novel additive manufacturing process for tungsten carbide.<br /> - Evaluate the degradation resistance of the newly manufactured materials and identify governing wear and corrosion mechanisms.<br /> - Use relationships between the manufacturing process and degradation processes to enhance manufacturing performance and deliver more durable tungsten carbide components for demanding industrial applications.<br /> <br /> During the PhD, the successful candidate will establish benchmark erosion-corrosion performance data for conventionally manufactured tungsten carbide, and begin development of the additive manufacturing process. The focus will then shift to the production and characterisation of novel tungsten carbide materials, alongside detailed erosion-corrosion testing and mechanistic investigations to understand degradation behaviour. Finally, insights into the relationships between manufacturing conditions, microstructure, and performance will be used to enhance the process and maximise material durability.<br />

<p><strong>Background</strong><br /> Tungsten carbide is widely used in sectors such as energy, aerospace, and manufacturing because of its exceptional resistance. Conventional manufacturing routes can limit design flexibility and increase production costs, however, powder-based additive manufacturing methods remain challenging for refractory metal composites. As components are increasingly required to operate in aggressive environments involving solid particle erosion and electrochemical corrosion, there is a growing need for innovative manufacturing approaches that deliver enhanced performance and durability. This project addresses this challenge by developing a novel sintering-based additive manufacturing process and establishing how manufacturing influences the degradation and reliability of tungsten carbide in demanding environments.</p> <p><strong>Methodology</strong><br /> This project will employ a novel additive manufacturing process developed by Hydra Manufacturing to produce tungsten carbide. The manufactured samples will be subjected to erosion-corrosion testing using a submerged impinging jet flow apparatus, which simulates aggressive environments by exposing materials to high-velocity corrosive fluids containing solid particles. Material degradation will be quantified and surface damage assessed using advanced materials characterisation techniques, including electron microscopy and surface profilometry. By establishing relationships between manufacturing, material characteristics and degradation performance, the project will generate the knowledge required to optimise the manufacturing process and enhance the durability of tungsten carbide for demanding industrial applications.</p> <p><strong>Skills Required</strong><br /> The candidate must hold, at minimum, a bachelor’s degree in either mechanical engineering, manufacturing, chemical engineering, material science, or related field. Strong data analysis skills are required, alongside critical thinking and communication skills. Laboratory experience and basic understanding of electrochemistry and manufacturing are desirable but not required.</p> <p><strong>Industry/external partners</strong><br /> This project is supported by Hydra Manufacturing, a spin-out company from the University of Leeds, which has developed innovative manufacturing technologies for producing tungsten carbide components. These novel manufacturing processes will form a core part of the research programme. The successful candidate will benefit from close collaboration with industry, including technical guidance and mentoring from Dr Dan Davie, Chief Scientist and Co-Founder of Hydra Manufacturing.<br />  </p>

<p>To apply for this project you will need to <a href="https://www.leeds.ac.uk/research-applying/doc/applying-research-degrees">make a formal application for research degree study through the University's website</a>. You will need to create a login ID with a username and PIN. </p> <ul> <li>For <strong>‘Application type’</strong> please select <strong>‘Research Degrees – Research Postgraduate’. </strong></li> <li>The <strong>admission year</strong> for this project is<strong> 2027/28 Academic Year.</strong></li> <li>You will need to select your <strong>‘Planned Course of Study’</strong> from a drop-down menu. For this project, scroll down and select <strong>‘EPSRC DLA (Engineering, Biological Sciences, Medicine)’ </strong></li> <li>The project start date for this project is <strong>01/10/2027</strong>, please use this as your <strong>Proposed Start Date of Research</strong>. </li> <li>Please state clearly in the research information section that the research degree you wish to be considered for is <strong>‘Advanced Manufacturing of High-Performance Tungsten Carbide for Demanding Environments’</strong> as well as <a href="https://eps.leeds.ac.uk/mechanical-engineering/staff/6998/dr-joshua-owen">Dr Joshua Owen</a> as your proposed supervisor.</li> </ul> <p><strong>Please state clearly in the finance section that the funding you are applying for is EPSRC Doctoral Landscape Award 2027/28: Mechanical Engineering.</strong></p> <p>You will be required to provide a personal statement which outlines your interest in the project you are applying for, why you have chosen it and how your skills map onto the requirements of the project. </p> <p><strong>Please note that you must provide the following documents in support of your application by the closing date of 18 November 2026 or at the point you submit your application:</strong></p> <ul> <li>Full Transcripts of all degree study or if in final year of study, full transcripts to date including grading scheme</li> <li>Personal Statement outlining your interest in the project</li> <li>CV</li> </ul> <p>If English is not your first language, you must provide evidence that you meet the University's minimum English language requirements (below).</p> <p><em>As an international research-intensive university, we welcome students from all walks of life and from across the world. We foster an inclusive environment where all can flourish and prosper, and we are proud of our strong commitment to student education. Across all Faculties we are dedicated to diversifying our community and we welcome the unique contributions that individuals can bring, and particularly encourage applications from, but not limited to Black, Asian, people who belong to a minority ethnic community, people who identify as LGBT+ and people with disabilities. Applicants will always be selected based on merit and ability.</em></p>

Applicants to research degree programmes in the School of Mechanical Engineering should normally have at least a first class or an upper second class British Bachelors Honours degree (or equivalent) in an appropriate discipline. Applicants are advised to check with the relevant School prior to making an application. Applicants who are uncertain about the requirements for a particular research degree are advised to contact the supervisor or Admissions Team prior to making an application.

The minimum English language entry requirement for research postgraduate research study is an IELTS of 6.0 overall with at least 5.5 in each component (reading, writing, listening and speaking) or equivalent. The test must be dated within two years of the start date of the course in order to be valid. Some schools and faculties have a higher requirement.

<p>A highly competitive EPSRC Doctoral Landscape Award (DLA) providing full academic fees, together with a tax-free maintenance grant at the standard UKRI rate (currently £21,805 in academic session 2026/27) for 3.5 years and rising annually, in line with standard UKRI rates. Training and support will also be provided.</p> <p>This opportunity is open to UK applicants only. </p> <p><br /> <strong>Competition funded  </strong></p> <ul> <li>"Competition funded" means that we advertise a larger number of projects than available awards. Not all projects advertised for this funding opportunity will receive funding. The selection panel will consider all applications received across the full range of advertised projects and select the awardee/s based on the strength of their application. </li> </ul> <p><br /> <strong>Eligibility Criteria </strong></p> <ul> <li>Applicants must be eligible to pay fees at the Home (UK) rate.</li> </ul> <p class="MsoNoSpacing"><br /> <strong>Other Conditions</strong></p> <ul> <li class="MsoNoSpacing">Candidates who have previously been awarded a PhD or are currently registered on a PhD are excluded from applying. Those who were previously studying for a PhD but did not complete may be considered. </li> <li>Awards must be taken up by 1st October 2027.</li> <li>Applicants must live within a reasonable distance of the University of Leeds whilst in receipt of this scholarship.</li> </ul> <p><br /> If you are unsure whether you are eligible for UK fees/funding, please see our <a href="https://www.leeds.ac.uk/undergraduate-fees/doc/fee-assessment">fee assessment page.</a></p> <p> </p>

<p>For further information please contact the PGR Admissions Engineering and Physical Sciences team on this email address: <a href="http://phd@engineering.leeds.ac.uk/">phd@engineering.leeds.ac.uk</a></p> <p>If you are interested in this project or have any questions, please do contact the project supervisor <a href="https://eps.leeds.ac.uk/mechanical-engineering/staff/6998/dr-joshua-owen">Dr Joshua Owen</a> on this address: <a href="mailto:J.J.Owen@leeds.ac.uk">JJ.J.Owen@leeds.ac.uk</a></p>