Academic ConnectPhD Position on Multi-Material Additive Manufacturing: Manufacturability, Microstructure, and Mechanical Properties
100%, Zurich, fixed-term
The Advanced Manufacturing Lab (AMLZ) is opening a PhD position to kick-start a five-year Franco-Swiss research project on the manufacturing, characterization, and modeling of additively manufactured multi-material parts. Focusing on one additive manufacturing process, Laser Powder Bed Fusion (LPBF), this first PhD project will lay the groundwork for understanding the feasibility and mechanical properties of bi-material parts.
The topic of this PhD will include (but is not limited to):
- Chemical compatibility of iron-based and nickel-based alloys in additive manufacturing processes (focusing on LPBF) using thermodynamic simulations and experimental approaches.
- Methodology to characterize the mechanical behavior of heterogeneous parts and gradient materials, with a focus on the experimental approach (modeling is possible).
- Bi-material interface geometries and their role in feasibility and mechanical behavior.
Project Background
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 is a collaboration between ISAE SUPAERO and ETH Zurich that aims to produce and characterize multi-material parts using LPBF, 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 is the first of three planned for the FASTE project between 2025 and 2030. It will explore the compatibility of an iron-based and a nickel-based alloy for bi-material parts made by LPBF, from process development to mechanical characterization. Starting in the second year, the optimized interfaces developed by this thesis will be produced using DED and WAAM through a second PhD thesis based at ISAE SUPAERO, Toulouse. This will foster collaboration and validate the methodology's repeatability and reliability.
Job Description
Technical Scope:
The candidate will explore the compatibility of iron-based and nickel-based alloys for making bi-material parts by LPBF and characterize the mechanical behavior of such parts.
- How to make bi-material LPBF parts?
Experimental trials (using Aconity Midi+) and thermodynamic simulations (ThermoCalc or equivalent) will help identify defects and their formation mechanisms (e.g., precipitation, cracks) and ways to mitigate them (process optimization, intermediate alloying, etc.). 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 custom methodology and test bench for bi-material parts will be developed, including selecting appropriate instrumentation (local and global strain measurements, temperature). The thesis may extend to studying more complex loadings (fatigue, high temperature, etc.).
The candidate will gradually take on responsibility for project management, scientific communication and publication (national and international conferences), teaching activities, 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 AMLZ group, Zurich, with occasional travel to ISAE SUPAERO, Toulouse.
- Preferred start date: March-April 2025.
- PhD diploma awarded by ETH Zurich: ETH requirements.
Your Profile
Soft Skills:
- Highly motivated! You're here for a reason!
- Proactive, willing to try new things, curious, and independent – a true researcher!
- Good character! Collaboration, communication, and organization are important. If you're not a people person, at least be a team player!
Hard Skills:
- Master's degree in materials science, mechanical engineering, or an equivalent field
- Knowledge of metallic additive manufacturing, particularly LPBF
- Knowledge (experience is a real plus) of material characterization (microscopy, mechanical testing, and monitoring)
- Proficiency in English (German/French beneficial)
- CH/EU/EFTA citizenship or a valid Swiss work permit
- The following competencies aligned with ETH Zurich's values are also desirable:
- Acting responsibly and professionally
- Driving innovation by:
- Being courageous, open, and curious
- Being flexible and adaptable to change
- Exploring new ideas, solutions, and technologies
- Treating all people equitably (living inclusivity)
- Building bridges by:
- Communicating effectively within and outside of the IDEAS research group
- Seeking opportunities to collaborate
We offer
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).
We value diversity
In line with our values, ETH Zurich encourages an inclusive culture. We promote equality of opportunity, value diversity and nurture a working and learning environment in which the rights and dignity of all our staff and students are respected. Visit our Equal Opportunities and Diversity website to find out how we ensure a fair and open environment that allows everyone to grow and flourish.
Curious? So are we.
Please note that we exclusively accept applications submitted through our online application portal. Applications via email or postal services will not be considered.
We look forward to receiving your online application with the following documents:
Resume
Relevant academic transcripts
Motivation letter
(optional) Reference letter
Further information about: AMLZ, ISAE SUPAERO, ICA
Questions regarding the position can be directed to Noémie Martin, nmartin@ethz.ch (no applications).
Applications are open until February 2025, and the first feedbacks will be sent end of January 2025.
