Associate Editor, Journal of Thermal Spray Technology
Associate Editor, Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology
My research team focuses on surfaces, interfaces and coatings technology for energy applications. My research interest lies in the understanding of novel materials manufacturing processes specifically Thermal spray and cold gas dynamic spray for high value engineering applications. Process-microstructure-properties relationship is at the heart of my research. My latest research focus is in suspension and solution precursor thermal spraying to manufacture 10-50 um thin functional coatings from sub-micron to nanometer range feedstock particles.
We have recently developed comprehensive test facilities to evaluate the performance of various surface engineered coatings including controlled environment fireside corrosion test rig, superheated steam oxidation rig and erosion-corrosion rig for fluidized bed boilers. I am part of the Advanced Materials Research Group.
I received a PhD in Materials Manufacturing from the University of Nottingham, which was followed by an MSc in Manufacturing Engineering. In my doctoral research, I investigated the high strain-rate deformation of titanium alloys using a novel cold gas dynamic spraying (a near net shape/additive manufacturing) technique. The process is still at its early stages and has the potential to be established as a high deposition rate additive manufacturing technique. My contribution to the scientific community was to propose a novel bonding mechanisms in the solid-state particle deformation. I am also a graduate in Mechanical Engineering.
Following my doctoral research, I worked as a research fellow (academic) at the Cranfield University, where my research was focused on high temperature performance of advanced materials and coatings for low carbon power generation technologies. I was involved in developing high velocity oxy-fuel coatings, plasma spraying coatings, laser deposited coatings, as well as diffusion slurry coatings for ultra supercritical power plants and biomass fired boilers. I designed a programme of research for two large TSB funded projects and implemented the research plan on a large EU FP7 funded project . I was the course director for MSc in Offshore and Ocean Technology with Materials Engineering.
I welcome inquiries from potential PhD candidates with an outstanding academic record and an interest in Thermal and Cold Sprayed Coatings, Surface Engineering and Materials for Energy.
Current Research Grants
- Improved Wear resistant Coatings Applied Internally on Complex Shapes, 2017-18, Innovate UK
- Microstructure characterization of disk alloys, 2017-18, Rolls-Royce Plc
- Tribology of nanocomposite coatings for Aerospace Applications, 2017- 2021, Rolls-Royce Plc
- EPSRC funded Ultra-Supercritical (USC) steam power generation technology with Circulating Fluidized Bed (CFB): Combustion, Materials and Modelling, £1.1 m. Materials work-package lead. http://gow.epsrc.ac.uk/NGBOViewGrant.aspx?GrantRef=EP/M01536X/1
- Thermal spraying for tribology applications, 2015-16, Rolls-Royce Plc (Aerospace)
- High velocity oxy fuel spray for internal surfaces, 2015-19, Monitor Coatings Ltd
- Cold spray deposition of precipitation hardenabe Al alloy, 2015-19, TWI
- Fe based coatings for application in biomass boilers, 2014-17, EON Technologies (Ratcliffe) Ltd
- Ceramics for application in power plants, 2014-17, Rolls Royce Plc (Nuclear)
- Low pressure cold spray repair of Al 6xxx carriages, 2015-16, Bombardier Transport
- Suspension HVOF spray of alumina, 2015-16, Wallwork HT Cambridge
- Biomass and Fossil Fuel Research Alliance (BF2RA) funded Development of novel coatings for biomass boilers, 2012-2015,(Held at Cranfield Uni.)
IOM3 monthly magazine, Materials World, http://www.iom3.org/feature/academia-or-industry
University of Nottingham Staff Spotlight, http://www.nottingham.ac.uk/engineering/newsevents/newslist/staff-spotlight-on-tanvir-hussain.aspx
Materials Manufacturing Processes: High Velocity Oxy-fuel Spraying (HVOF), Cold Gas Dynamic Spraying (CGDS), and novel Solution Precursor/ suspension thermal spray for various applications (e.g., solid oxide fuel cells, solar cells etc).
Materials for Energy Applications: Fireside corrosion degradation of thermal sprayed coatings, laser claddings and alloys for biomass fired steam generator; Steamside oxidation of coatings and alloys for ultra supercritical (USC) power plants; degradation of ceramics in pressurized water reactors.
I am the year 1 lead on our Aerospace Engineering Degree programme.
I teach in the following modules
- H41AD1 Aerospace Design and Materials 1: I teach fundamental Materials Engineering
- MM3AMT Aerospace Manufacturing Engineering: I teach Aerospace Materials and Manufacturing
I have a keen interest in Materials for Energy applications and I regularly supervise MEng and BEng final year students and MSc students on that topic.
I am Fellow of the Higher Education Academy (FHEA) and have a post graduate certificate (PGCert) in academic practice.
Suspension and Solution precursor thermal spraying: We have commissioned the UK's first direct injection suspension and solution precursor HVOF thermal spray in 2015. We are studying the process-… read more
Suspension and Solution precursor thermal spraying: We have commissioned the UK's first direct injection suspension and solution precursor HVOF thermal spray in 2015. We are studying the process- microstructure- properties relationship of various ceramic materials, which are prepared from sub-micrometre to nanometre sized powder feedstock dispersed in water and alcohol. The research is focused on functional materials for energy applications to provide step changing technological solutions.
High Velocity Oxy-Fuel spraying: Work continues on the development of coatings using High Velocity Oxy Fuel (HVOF) spraying for power generation industry to combat aggressive fireside corrosion in the pulversied fuel and the fluidised bed boilers. We are developing novel multi-layered coatings for ultra supercritical power plants, which operate at higher temperatures (and pressures) thus increasing efficiency and reducing CO2 footprint. Process-property-performance of HVOF sprayed coatings in fossil fuel fired and co-fired (biomass/ waste) boilers are of great interest to us.
Cold Gas Dynamic Spraying: The work concerns the process development of cold gas dynamic spraying (CGDS) as a surface engineering tool, as well as a near net shape manufacturing technique. The work is supported by high speed laser particle image velocimetry (PIV), mercury intrusion porosimetry, pycnometry, ASTM pull-off adhesion tests and a state-of-the art material characterisation laboratory. Current research focuses on cold spraying of copper, aluminium, titanium and nickel based alloys. I am interested in understanding the bonding mechanisms in the high strain rate deformation process in cold-spraying. We are currently developing a micro cold spraying system for direct writing and additive manufacturing.
Laser cladding: As part of the significant research interest in the laser manufacturing processes at the school of engineering, my interests lie in the microstructure- performance relationship of the laser claddings for the heat exchangers (superheaters/ reheaters) in power plants. Current projects are developing high temperature corrosion resistant laser claddings for biomass fired boilers. I also have a keen interested in laser surface treatment of thermal sprayed coatings.
Sustainable materials and sustainable materials manufacturing processes for energy applications