Best practices for minimising dross formation during melting of scrap aluminium

The research addresses dross formation — a significant material loss during aluminium scrap recycling caused by oxidation and impurities. The project is a collaboration between Brunel University's BCAST and Constellium, focusing on establishing best practices to reduce dross by studying scrap surface characteristics, optimizing melting parameters, and introducing oxide growth inhibitors. As a student, you will engage in comprehensive experiments involving scrap preheating, furnace atmosphere control, and melting cycle optimizations. You will collaborate with industrial and academic supervisors, using advanced characterization techniques such as microstructural analysis and chemical surface analysis to understand and minimize dross formation. Expected Outcomes The project aims to deliver actionable guidelines to improve aluminium recycling efficiency by reducing dross formation, thus saving material losses and lowering environmental impact. The research findings will inform industrial practices and contribute to lightweighting applications for sustainable manufacturing. Why It Matters Reducing dross formation enhances metal recovery and cuts production costs while decreasing environmental waste. This research supports the circular economy in aluminium production by improving recycling processes and fostering collaboration between academia and industry.

Applicants should have, or expect to receive, a first or upper-second class honours degree in Materials Science, Mechanical Engineering, Chemical Engineering, Physics, or related fields. Essential qualification includes strong background in physical metallurgy, materials science or chemistry, and experience with casting, heat treatment, microstructural characterisation, surface chemical analysis, and differential scanning calorimetry. Highly motivated individuals with good communication skills and ability to work independently and in teams are preferred. Eligibility for home tuition fees via UK nationality, residency, or other UK connection is required.

Submit your application documents as one PDF file to mtsthbn@brunel.ac.uk by noon on 2026-03-09. Required documents include an up-to-date CV, a personal statement (300-500 words), degree certificates and transcripts, evidence of English language skills if applicable, and contact details for two referees (one academic preferred). Mention the project title at the top of your personal statement. Interviews will be arranged shortly after the deadline.