Development of high-performance ferrous alloys through additive manufacturing

Mechanical properties of ferrous alloys such as steels are governed by their chemical composition and thermal processing.

In conventional manufacturing processes, high strength can be achieved through increasing the carbon contents and/or heat treatment such as fasting from high temperature. However, this approach also leads to embrittlement and even cracking due to the formation of high carbon martensite.

In addition, such a strengthening approach is restricted by the size of parts. Parts with large cross-sections are hard to be strengthened because of the limitation of the hardenability of ferrous alloys.

Those problems can be overcome by metal additive manufacturing (also called metal 3D printing) by leveraging of the features 3D printing. This includes sequential microscale melting and rapid cooling. The former enables homogenous microstructure, and the latter leads to refined grains.

Grain refinement is an effective approach to simultaneously increase strength and toughness of metals. But grain refinement of steels is difficult as steels are hard to be inoculation-treated in conventional processes. During 3D printing, inoculation can be done during feedstock preparation. Our previous work has verified the feasibility of this.

The School of Mechanical and Mining Engineering at UQ has historical strengths in materials research and has been internationally recognised as one of the world’s leading research institutions on metallic materials and manufacturing.

The AMPAM Centre provides a unique platform for both materials and manufacturing research. There are ongoing ARC Discovery and/or linkage projects supporting this research.

UQ materials engineering has received the ARC ERA rating of 5 in all years.

The SoMME hosts the largest laboratory foundry in Australia, which can ensure the success of the proposed project. 

There are also a well-equipped mechanical testing laboratory and a metallographic laboratory.  In addition, UQ has a world-class Centre for Electron Microscopy and Microanalysis that you can access.

This project is supported by the Research project scholarship.

Learn more about the Research project scholarship.

Your application will be assessed on a competitive basis.

We take into account your:

• previous academic record
• publication record
• honours and awards
• employment history.

A working knowledge of metallic materials would be of benefit to someone working on this project.

You will demonstrate academic achievement in the fields of materials/mechanical and/or chemical engineering and the potential for scholastic success.

A background or knowledge of additive manufacturing and metals is highly desirable.

You must submit an expression of interest (EOI) by 29 October, 2026 29 October, 2026.

Before you apply

1. Check your eligibility for the Doctor of Philosophy (PhD).
2. Prepare your documentation.
3. If you have any questions about whether the project is suitable for your research interests, contact Professor Mingxing Zhang (Mingxing.Zhang@uq.edu.au).

When you apply

To apply, submit an expression of interest (EOI) for the program. You don't need to apply separately for the project or scholarship. How to submit an EOI

In your EOI, complete the ‘Scholarship/Sponsorship’ section with the following details:

1. Are you applying for an advertised project: 'Yes'
2. Project: 'Research project scholarship'
3. Scholarship Code Listed in the Advertisement: FERROUS-ZHANG
4. Link to Scholarship Advertisement: https://study.uq.edu.au/study-options/phd-mphil-professional-doctorate/projects/development-high-performance-ferrous-alloys-through-additive-manufacturing

Submit an EOI