PhD position on multi-material additive manufacturing: manufacturability, microstructure and mechanical properties

The Advanced Manufacturing Lab (AMLZ) opens a PhD position to kick-start a 5-years Franco-Swiss research project on the manufacturing, characterization and modelling of additively manufactured multi-material parts. Focussing on one additive manufacturing process, Laser Powder Bed Fusion, this first PhD will lay the basis of feasibility and mechanical properties of bi-material parts.

The topic of interest of this PhD include (but are not limited to):

• Chemical compatibility of iron-based and nickel-based alloys in AM processes (focus on LPBF): thermodynamic simulation and experimental approaches
• Methodology to characterize the mechanical behavior of heterogeneous parts and gradient materials: experimental aproach, (modelling possible)
• Bi-material interface geometries and role on the feasibility and mechanical behavior

This PhD thesis is part of the FASTE (Fabrication Additive des Structures performantes multi-maTériaux pour utilisation en Environnement sévère) project, funded by the 2024 Lopez-Loreta foundation prize. FASTE, a collaboration between ISAE SUPAERO and ETH Zürich, aims to produce and characterize multi-material parts using LPBF (Laser Powder Bed Fusion), DED (Direct Energy Deposition), and WAAM (Wire Arc Additive Manufacturing) technologies. The project encompasses manufacturing methodologies, mechanical behavior characterization, and modeling under complex loads, focusing on multi-material parts.

This thesis the first of the three planned in FASTE, between 2025 and 2030. It explores the compatibility of a iron-based and a nickel-based alloy for bi-material parts made by LPBF, from process development to mechanical characterization. Starting the second year, the optimized interfaces developped by this thesis will be produced using DED and WAAM through a second PhD thesis based at ISAE SUPAERO, Toulouse, fostering collaboration, and validating the methodology's repeatability and reliability.

Technical scope :
The candidate will explore the compatibility of iron-based and nickel-based alloys to make bi-material parts by LPBF, and characterize the mechanical behavior of such parts.

• - How to make bi-material LPBF parts?
  Experimental campaigns (Aconity Midi +) and thermodynamic simulations (ThermoCalc or equivalent) will help identify defects and their formation mechanisms (e.g., precipitation, cracks) and seek to mitigate them (process optimization, intermediate alloying…). Post-treatments like heat treatments and machining will be considered.
• What is the mechanical behavior of such parts ?
  The candidate will set up testing methodologies to characterize and understand the quasi-static mechanical behavior (tensile and shear loading) of multi-material LPBF parts. A bespoke methodology and test-bench for bi-material parts will be developed, including instrumentation selection (local and global strain measurements, temperature). The thesis may extend to more complex loadings (fatigue, high temperature…).
• The candidate will gradually take responsibility for project management, scientific communication and publication (national and international conferences), teaching activites, and other research and academia-related tasks relevant to a PhD position (up to 20% of the time).

Administrative scope :

Full-time position in the group AMLZ, Zürich, with occasional travel to ISAE SUPAERO, Toulouse. Preferred start date: March-April 2025.
PhD diploma awarded by ETH Zürich: ETH requirements.

Some soft skills :

• Really motivated ! You're here, and you know why !
• Proactive, ready to try new things, curious, autonomous: let's say, research oriented !
• Good character ! Collaboration, communication, organization... If not a people person, at least a team person !

Some hard checks :

• Master’s degree in materials science, mechanical engineering, or equivalent
• Knowledge of metallic additive manufacturing, in particular LPBF
• Knowldedge (experience is a real plus) on material characterization (microscopy, mechanical testing and monitoring)
• Proficiency in English (German/French beneficial)
• CH/EU/EFTA citizenship or valid Swiss work permit

We also would like you to bring the following competencies in line with ETH Zurich’s values:

• You act responsibly and professionally
• You can drive innovation, e.g. by
  • Being courageous, open, and curious
  • Being flexible and adaptable to change
  • Exploring new ideas, solutions, and technologies
• You live inclusivity by treating all people equitably
• You build bridges, e.g. by
  • Communicating effectively inside or outside of our IDEAS research group
  • Seeking opportunities to collaborate

The candidate will beneficiate from both ETH and ISAE SUPAERO well established institutions (administrations, Masters and Bachelors courses, labs and skills...), as well as participate in the shaping up of the project, with a lot of flexibility !

The advanced manufacturing lab at ETH (AMLZ) develops new manufacturing technologies that overcome the limitations of today's processes, with a focus on additive and hybrid manufacturing processes and advanced process control. ISAE SUPAERO and ICA represent a strong competencies center in aeronautical materials and structure development. The collaboration of the two will bring flexibilitity, and a lot of opportunities to this PhD project in terms of training, network, accessible means...

The day to day supervising will be ensured by Dr Martin (AMLZ), project manager of FASTE, as well as the support from the AMLZ team in particular Dr Deillon (AMLZ), senior scientist and lecturer at ETH. The PhD will be directed by Pr Bambach (AMLZ, ETH) and co-directed by Dr Hor (DMSM, ISAE SURAERO).