Dean's Fellowship- Advanced Materials and Manufacturing for Energy, Faculty of Engineering
I lead a team of doctoral and post doctoral researchers in advanced materials processing for energy applications. I am a member of the Cleaner Fossil Energy and Carbon Capture Technology Research Group and an associate member of the Advanced Materials Research Group. My research interest lies in the understanding of novel materials manufacturing processes specifically thermal spray, cold gas dynamic spray, laser cladding and weld overlay for advanced engineering applications. Process-microstructure-properties relationship is at the heart of my research and we have recently developed comprehensive test facilities to evaluate the performance of various surface engineered coatings.
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 in collaboration with The Welding Institute (TWI). 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 (ASPECT and ASPIRE) and implemented the research plan on a large EU FP7 funded project (NEXTGENPOWER). I was the course director for MSc in Offshore and Ocean Technology with Materials Engineering.
I am currently open to hear from potential PhD students, who are interested in surface engineering and manufacturing technologies in the power generation sector.
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
Current Research Grants
- Co-Investigator in EPSRC (EP/M01536X/1) funded Ultra-Supercritical (USC) steam power generation technology with Circulating Fluidized Bed (CFB): Combustion, Materials and Modelling, £1.1 m. Materials work-package lead. We will be building a novel erosion-corrosion test rig for materials in CFB. http://gow.epsrc.ac.uk/NGBOViewGrant.aspx?GrantRef=EP/M01536X/1
- Fe based coatings for application in biomass boilers, £25k, 2014-17, Principal Investigator (PI), EON Technologies (Ratcliffe) Ltd
- Ceramics for application in power plants, PI, £68k, 2014-17, Rolls Royce Plc
- Low pressure cold spray repair of Al 6xxx carriages, PI, £29 k, 2015-16, Bombardier Transport
- Suspension HVOF spray of alumina, PI, £23k, Wallwork HT Cambridge
- Biomass and Fossil Fuel Research Alliance (BF2RA) funded Development of novel coatings for biomass boilers, £40k, 2012-2015, Co-I, (Held at Cranfield Uni.)
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
Materials Manufacturing Processes: High Velocity Oxy-fuel Spraying (HVOF), Cold Gas Dynamic Spraying (CGDS), Laser material deposition (wire and blown powder) and novel Solution Precursor/ suspension thermal spray for various applications (e.g., solid oxide fuel cells, solar cells etc).
Teaching summaries for 2013-14 Spring Semester
- MM3AMT Aerospace Manufacturing Technology (20%)
Aerospace Materials, Aerospace Manufacturing Technologies (Non- conventional machining)
- MM1DM1 Design and Manufacture 1 (30%)
I am Fellow of the Higher Education Academy (FHEA) and have a post graduate certificate (PGCert) in academic practice.
In my previous role at Cranfield University, I was the course director for Offshore and Ocean Engineering with Materials Engineering. I was the module leader for Offshore Inspection and Corrosion in Offshore module. I have given lectures on mechanical properties of materials related to power plants, heat exchangers in advanced power plants, phase diagrams, mass balance for fuels/combustion (waste to energy, biomass co-firing), electric energy storage & thermal energy storage and small- large scale hydro electricity.
Suspension/ Solution precursor thermal spraying: We have commissioned the UK's first direct injection suspension/ solution precursor HVOF thermal spray in 2015. We are studying the process-… read more
DUDZIAK, T., HUSSAIN, T., SIMMS, N. J., SYED, A. U. and OAKEY, J. E., 2014. Fireside corrosion degradation of ferritic alloys at 600 degrees C in oxy-fired conditions CORROSION SCIENCE. 79, 184-191 HUSSAIN, T., DUDZIAK, T., SIMMS, N. J. and NICHOLLS, J. R., 2013. Fireside Corrosion Behavior of HVOF and Plasma-Sprayed Coatings in Advanced Coal/Biomass Co-Fired Power Plants JOURNAL OF THERMAL SPRAY TECHNOLOGY. 22(5), 797-807
HUSSAIN, T, MCCARTNEY, DG, SHIPWAY, PH and MARROCCO, T, 2011. Corrosion Behavior Of Cold Sprayed Titanium Coatings And Free Standing Deposits Journal of thermal Spray Technology. 260-274
Dominka Orlicka (2012- current), Developement of Novel Coatings for Fireside Corrosion Protection in Biomass Fired Boilers, jointly with Dr.Nigel Simms, Cranfield University
The project is sponsored by BF2RA (Biomass and Fossial Fuel Research Alliance) and co-supervised by EON New Build and Technology, Nottingham. Dominika is developing novel coating compositions using a multiple target PVD coater to produce a range of compositions for exposure in a simulated biomass fired combustion environment. The shortlisted compositions will be used to produce powders, which will be deposited onto heat exchangers using a thermal spraying technique.
Bo Song (2013- current), Development of HVOF and laser cladded WC-NiCr coatings for heat-exchangers in biomass fired boilers, principal supervisor
The project is looking at co-deposition of NiCr (50:50) with spherical WC to produce a corrosion as well as erosion resitant coatings in pulversied fuel biomass fired boilers. Currently, a power based laser cladding system and a high velocity oxy-fuel methods are being investigated.
Liam Reddy (2014- current), Fe based coatings for biomass boilers, EON Technologies (Ratcliffe) Ltd, Principal supervisor
This is an EngD project based at the Efficient Fossil Energy Technologies (EFET) engineering doctorate Centre and funded by EON Technologies (Ratcliffe) Ltd. The fundamental challenge to be addressed in this project is to develop iron based nanostructured coatings from laser cladding and thermal spraying for the next generation of biomass boilers. Laser Cladding Technologies (LCT) is an industrial collaborator in this project.
Gilbert Karimi (2014- current), Degradation of ceramics in hydrothermal corrosion, Principal supervisor
Suspension/ Solution precursor thermal spraying: We have commissioned the UK's first direct injection suspension/ 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.
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.
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.
Sustainable materials and sustainable materials manufacturing processes for energy applications