Application of Closed-loop control for EBeam Powder Bed Fusion manufacture of Tungsten – employing Dynamic Process Themes and Microstructural Control in Fusion Engineering component manufacture.

University of Sheffield, United Kingdom

Updated: about 13 hours ago

Location: Sheffield, ENGLAND

The Fusion Engineering Centre for Doctoral Training (CDT)

PhD Research Project Directly Funded UK Students

Prof I Todd

Application Deadline: 31 July 2025

Details

This EngD research aims to revolutionize Electron Beam Powder Bed Fusion Additive Manufacturing (AM) through the use of thermodynamic and process model informed edge compute closed-loop control systems. Focusing on thermal compensation within the manufacturing process, the study seeks to implement dynamic process themes that adapt to real-time thermal variations – and in so doing control precisely the microstructures that can be developed Metals and alloys in the Electron Beam Process. By integrating closed-loop control mechanisms, this project aims to enable the production of novel component architectures in W and Smart-W for Fusion, exerting precise microstructural control to enable their use in future fusion reactor programmes.

Through rigorous experimentation and analysis, the study intends to establish a comprehensive framework that enables the adjustment of manufacturing strategies to enhance the precision, reliability, and quality of EBAM-produced components. This research is poised to contribute significantly to advancing the capabilities of AM technology, fostering greater efficiency and consistency in production while expanding the potential material and component application.

The project sits within the Fusion Engineering CDT, which is a collaboration between several UK universities. This project will be linked to an engineering environment, and therefore applicants would need to evidence an understanding of the UK energy mix. Canidates will be given foundational training in fusion engineering as part of the cohort, and supported to complete a portfolio to support CEng status. For more information about the CDT programme please visit www.fusion-engineering-cdt.co.uk.

This EngD project is industrially co-supervised at Freemelt, and the candidate should expect to spend considerable time with the industrial partner.

Please direct project enquiries to the academic supervisor, Professor Iain Todd at iain.todd@sheffield.ac.uk, or questions about the CDT to the Centre Manager at fusion-engineering@sheffield.ac.uk.

fusion_cdt

Funding Notes

Students will recieve a 4-year studentship including home tution fees, UKRI stipend (£20,780 in 25-26) and a RTSG budget for project costs. All costs associated with attending CDT training will be met by the CDT.

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