Optimisation of thermomechanical ageing processing: influence of quenching and pre-ageing on the performance of high strength 6xxx aluminium alloys

Applications are invited for a full-time EPSRC Industrial Doctoral Landscape Awards (IDLA) PhD studentship in research on Optimisation of thermomechanical ageing processing: influence of quenching and pre-ageing on the performance of high strength 6xxx aluminium alloys at the Department of Materials, The University of Manchester and in collaboration with Constellium. The successful applicant will receive an annual stipend (bursary) plus payment of their full-time tuition fees for 4 years. As the automotive industry intensifies its shift toward lightweight, high-performance materials, high strength and high crush resistant AA6xxx AlMgSiCu aluminium alloys are presently the preferred choice for lightweight vehicle structures, including the body-in-white and for the light-weighting and the electrification of both on- and off-road vehicles. Optimised thermomechanical ageing process has pushed these alloys to new performance levels, but the quenching and pre-ageing steps, critical to controlling precipitation behavior and solute retention, remains insufficiently understood. This project addresses that gap by leveraging advanced microscopy to study microstructural evolution during thermomechanical processing, aiming to refine alloy design and extrusion practices for automotive applications. The work will focus on how quenching rate and pre-ageing steps influence microstructural evolution and performance of AA6xxx aluminium alloys processed via advanced thermomechanical processes. Key questions include: i) how does quenching affect precipitate formation, PFZs, and thermomechanical ageing response; ii) how do variations in alloy chemistry (Si, Mg, Cu) impact quench sensitivity and precipitation behaviour; iii) what role do pre-ageing conditions—temperature, duration, and natural ageing time—play in shaping microstructural response during aging; iv) how do resultant microstructural features correlate with mechanical properties and corrosion resistance. Correlative accelerated laboratory testing and analytical electron microscopy will be employed. The programme provides a unique opportunity to combine academic research with industrial experience. The student will work closely with Constellium, gaining exposure to industrial manufacturing environments, alongside standard EPSRC and industrial-sponsored stipend.

Applicants should have or expect to achieve at least a 2.1 honours degree in materials science/engineering, metallurgy, physics, chemistry, or a related subject.

Submit an online application through The University of Manchester portal: https://uom.link/pgr-apply
. Include transcripts, CV, supporting statement, and referee contacts. Contact Prof X Zhou (xiaorong.zhou@manchester.ac.uk) for guidance.