Robotic Additive Manufacturing for Remote In-situ Repair of Vertical Tungsten Plasma-facing Tiles in Tokamaks PhD

We are seeking a strongly motivated candidate for a PhD in Robotic Additive Manufacturing for Remote In-situ Repair of Vertical Tungsten Plasma-facing Tiles in Tokamak Fusion Reactors. This research project, supported by EPSRC, Cranfield University and UKAEA, offers tuition fee coverage for UK home students and an annual bursary of £24,500. The project focuses on advanced manufacturing, robotic wire-based additive manufacturing, arc and laser directed energy deposition, thermal–mechanical modelling, and intelligent process monitoring and control for fusion energy applications.

Fusion energy has the potential to transform the global energy landscape by offering a low-carbon, sustainable source of energy, with the prospect of abundant fuel and no greenhouse gas emissions during operation. Realising this potential requires breakthroughs in advanced materials, manufacturing and engineering to withstand the extreme conditions inside fusion reactors. In tokamak fusion reactors, tungsten plasma-facing tiles are exposed to intense heat and particle flux, making them susceptible to damage and erosion over time. Repairing these components presents significant technical challenges, creating a need for innovative in-situ repair solutions. Robotic additive manufacturing offers an exciting opportunity to repair damaged components remotely, potentially reducing maintenance complexity, cost and reactor downtime.

This PhD project aims to develop a robotic additive manufacturing approach for the remote, in-situ repair of damaged vertical tungsten plasma-facing tiles in tokamak fusion reactors. The research will investigate and optimise wire-based directed energy deposition processes, including arc, laser and hybrid approaches, to achieve crack-free, geometrically stable tungsten deposition on vertical and inclined surfaces. By combining experimental investigations with thermal–mechanical modelling, the project will explore heat transfer, residual stress development and cracking mechanisms to improve the understanding and reliability of the repair process. The research will also investigate the influences of deposition orientation and robotic flexibility on repair quality, followed by developing a sensor-integrated monitoring and real-time feedback control system to enhance process stability, minimise defects and enable reliable remote repair under challenging conditions.

Cranfield University is a specialist postgraduate university with a strong focus on science, engineering, technology and innovation. This PhD project is supported by EPSRC, Cranfield University and the UK Atomic Energy Authority (UKAEA). UKAEA will contribute expertise in robotics and manufacturing processes through supervision, and the collaboration will provide opportunities to access UKAEA's associated robotics platforms and specialist materials. The student will also undertake an industrial placement of up to three months at UKAEA, gaining valuable practical experience in advanced robotics, manufacturing technologies and fusion-related engineering.

The research is expected to deliver optimised wire-based deposition processes, a validated thermal–mechanical model and practical guidelines for achieving stable, crack-free deposition on vertical and inclined tungsten surfaces. The development of sensor-integrated monitoring and control will further enhance process stability, geometric accuracy and repair quality. The outcomes will provide a validated repair methodology and improved understanding of tungsten deposition, supporting future applications in fusion reactor maintenance and contributing to the long-term reliability and commercial viability of fusion energy technologies.

Throughout the PhD, the student will develop a broad range of technical, analytical and transferable skills including experimental design, advanced manufacturing, thermal–mechanical modelling, data analysis, critical thinking and independent problem-solving. The student will also strengthen research planning, project management, teamwork, interdisciplinary collaboration, scientific writing and presentation skills. Funding is provided to attend national and international conferences. The student will be part of the Cranfield Doctoral Network and participate in the Doctoral Researchers' Core Development (DRCD) Programme.

Entry Requirements: Applicants should have a first or second class UK honours degree or equivalent in a related discipline. This project would suit motivated graduates from a broad range of backgrounds including manufacturing, materials, mechanical engineering, robotics, physics or other relevant scientific and technical disciplines. Candidates with an interest in advanced manufacturing, additive manufacturing, automation, materials processing or sustainable energy technologies are particularly encouraged to apply. Applications are encouraged from individuals of all backgrounds, including those from underrepresented groups and non-traditional educational pathways.

Funding: Sponsored by EPSRC and Cranfield University, this studentship will provide a bursary of up to £24,500 per annum (tax free) plus home fees for 3.5 years. The studentship is open to both Home and Overseas fee status students, however only a limited number of studentships are available to students with Overseas fee status.

Supervisors: 1st Supervisor: Dr Yongle Sun; 2nd Supervisor: Professor Stewart Williams.