PhD Opportunity - High Performance Electrical Insulation Coatings for Next Generation Additively Manufactured Electrical Machines
Are you a materials engineer or chemistry graduate looking to apply your background to next generation electrical technologies in pursuit of Carbon Net Zero? We are seeking a motivated PhD candidate to join The Electrical Machine Works, University of Bristol, to develop high-performance electrical insulation coatings and coating processes for metal 3D printed windings. The successful candidate will work in a multi-institution, multi-disciplinary team across material science, process development, design for additive manufacture and experimental testing with opportunity for industrial collaboration and commercialisation.
Context
Step improvement in electrical machine power density (kW/kg) is essential to the success of future More- and All-Electric transport initiatives and in achieving Carbon Net Zero targets. The Electrical Machine Works seeks to exploit the geometric freedom of metal Additive Manufacturing (AM) to simultaneously improve efficiency, thermal management, and electrical insulation temperature rating of electrical windings, Fig. 1, [1]. The use of AM to produce pre-formed windings eliminates the need for insulation coatings to exhibit a high degree of mechanical flexibility to withstand conventional winding processes. Hence, flexible organic based insulation materials, with their inherent thermal limitations (circa 240oC), can be substituted with high-performance inorganic based or organic-inorganic composite based insulation systems. Previous research at the partner university, [2-3], has proven the capability for inorganic insulation systems to operate reliably during long exposure at temperatures of up to 500oC. The PhD project will focus on the development of suitable coatings and controlled application processes on complex AM components with non-ideal surfaces, Fig. 2.
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Fig. 1: CuCrZr shaped profile winding (prior to coating) |
Fig. 2: Scanning Electron Microscope (SEM) image of Cu winding surface |
[1] N. Simpson et al., “Additive manufacturing of shaped profile windings for minimal ac loss in electrical machines,” IEEE Transactions on Industry Applications, May 2020. doi: 10.1109/TIA.2020.2975763
[2] Y. Pang et al., “Ceramic / inorganic-organic nano-hybrid composites for thermally stable insulation of electrical wires. part i: Composition and synthetic parameters,” IEEE Transactions on Dielectrics and Electrical Insulation, vol. 27, no. 2, pp. 395–402, 2020.
[3] Y. Pang et al., “Ceramic / inorganic-organic nano-hybrid composites for thermally stable insulation of electrical wires. part ii: Properties of the composite insulated wires,” IEEE Transactions on Dielectrics and Electrical Insulation, vol. 27, no. 2, pp. 403–409, 2020.
What will I be doing?
The successful candidate will join The Electrical Machine Works under a multidisciplinary supervisory team who will provide training and project supervision. The student will be involved in the following activities (non-exhaustive):
- Learning relevant underpinning material science, chemistry, and application context
- Development of mechanical-, chemical- and electro-polishing post-processes to control AM part surface roughness
- Undertake surface, bulk and material property characterisation via, for example, Scanning Electron Microscope (SEM), Computed Tomography (CT), Optimal profilometry, Grain structure analysis and electrical conductivity measurement
- In-depth study and development of coating technologies ranging from organics to inorganics
- Characterisation of coatings via optical, physical, and chemical means
- Review and development of highly controlled automated coating processes of complex AM parts
- Collaboration with industrial and academic partners within The Electrical Machine Works
- Regular dissemination of findings via internal and external meetings and events
- Publication of findings at appropriate international conferences and in journal proceedings
- Play an active role in the research group community for your own development and development of others.
Should I apply?
You should apply if you are a motivated, collaborative, materials engineer or chemistry graduate (or related field) at 2:1 or above with a desire to apply your background to highly multi-disciplinary problems with real world impact potential in stepping toward Carbon Net Zero.
Closing date
January 15th 2022
Earliest start date
September 20th 2022
Funding
Subject to contracts and eligibility criteria the scholarship, if successfully awarded, covers full UK/EU PhD tuition fees and a tax-free stipend at the current RCUK rate (£15,609 in 2021/22) for 3.5 years
Eligibility
To be eligible for a full award the student must have no restrictions on how long they can stay in the UK and have been ordinarily resident in the UK for at least 3 years prior to the start of the studentship (with some further constraint regarding residence for education). To be considered for funding Candidates must:
- Be a UK National (meeting residency requirements)
- (or) Have settled status
- (or) Have pre-settled status (meeting residency requirements)
- (or) Have indefinite leave to remain or enter.
Further Information
https://gow.epsrc.ukri.org/NGBOViewGrant.aspx?GrantRef=EP/T02125X/1
How to apply
If you meet the eligibility criteria, please direct enquiries to Dr. Nick Simpson via nick.simpson@bristol.ac.uk in the first instance.