Best practices for minimising dross formation during melting of scrap aluminium

Applications are invited for one full-time EPSRC Industrial CASE (ICASE) PhD studentship for the project “Best practices for minimising dross formation during melting of scrap aluminium”.

BCAST is a specialist research centre in metallurgy with a focus on processing metallic materials for lightweighting applications. The project is in collaboration with Constellium, a global leading manufacturer of high-quality, technically advanced aluminium products and systems.

Successful applicants will receive an annual stipend (bursary) starting from approximately £23,000 plus payment of their full-time home tuition fees for a period of up to 48 months (4 years).

In the aluminium recycling industry, dross formation represents a substantial material loss, with up to 5-10% of the charge potentially lost as dross. Dross primarily consists of aluminium oxides, impurities, and trapped metal, forming due to reactions between molten aluminium and atmospheric oxygen. Various factors contribute to excessive dross formation, including scrap condition, furnace type, melting cycle parameters, heating sources, and furnace atmosphere. Effective control of dross formation can improve metal recovery, reduce environmental impact, and lower production costs. Different scrap sources, such as end-of-life products, machining scrap, and production returns, present varying levels of contamination and oxide coatings, which can lead to inconsistencies in dross formation. By studying surface characteristics of scrap from various sources and implementing controlled preheat and environment, we can significantly reduce the oxidation of molten aluminium and minimise dross formation.

This studentship outlines a comprehensive study aimed at establishing best practices to minimise dross formation during the remelting of aluminium scrap sourced from various stages of the recycling process. Emphasis will be placed on optimising preheat treatments, melting cycle parameters, and furnace atmosphere control, alongside introducing specific elements/flux that inhibit oxide growth.

The project will be part of the activities of the Constellium University Technology Centre (UTC) established with BCAST. The successful candidate will have the opportunity to interact with researchers in BCAST and with Constellium’s industrial research engineers. An industrial supervisor of the project will be appointed by Constellium. This close collaboration provides a strong foundation for a future career, whether in industry or academia.

Please contact Prof. Hari Babu Nadendla for an informal discussion about the project.

Eligibility

Applicants will have or be expected to receive a first or upper-second class honours degree in Materials Science, Mechanical Engineering, Chemical Engineering, Physics, or a similar discipline. A postgraduate master’s degree is not required but may be an advantage.

A strong background in physical metallurgy, materials science or chemistry is essential, and experience in casting, heat treatment, microstructural characterisation, characterisation tools for surface chemical analysis, and differential scanning calorimetry.

In addition, applicants should be highly motivated, able to work independently as well as in a team, and have effective communication skills.

Applicants must be eligible for home tuition fees through either nationality, residency (living in the UK for at least three years and not wholly for educational purposes), or other connection to the UK.

How to apply

Please submit your application documents (see list below) in one PDF file by noon Monday, 2 June 2025 to cedps-pgr-office@brunel.ac.uk. Interviews will take place in June 2025.

• Your up-to-date CV
• Your personal statement (300 to 500 words) summarising your background, skills, and experience
• Your undergraduate / postgraduate degree certificate(s) and transcript(s)
• Evidence of your English language skills to IELTS 6.5 (or equivalent, 6.0 in all sections), if appropriate
• Contact details for two referees, one of whom can be an academic member of staff in the College

Remember to state the title of the project at the top of your personal statement.