Dean's Fellowship in Surface Engineering (Senior Research Fellow), Faculty of Engineering
I received a PhD in Materials Engineering 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.
Materials for energy: Fireside corrosion of thermal sprayed coatings/ alloys, Steamside oxidation of diffusion coatings/ alloys for ultra supercritical power plants
Surface engineering: High Velocity Oxy-fuel Spraying (HVOF), Cold Gas Dynamic Spraying (CGDS)/ manufacturing, Laser material deposition
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.
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… read more
HUSSAIN, T., MCCARTNEY, D.G., SHIPWAY, P.H. and ZHANG, D., 2009. Bonding mechanisms in cold spraying: the contributions of metallurgical and mechanical components Journal of Thermal Spray Technology. 18(3), 364-379 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 HUSSAIN, T., MCCARTNEY, D. G. and SHIPWAY, P. H., 2012. Bonding between aluminium and copper in cold spraying: story of asymmetry MATERIALS SCIENCE AND TECHNOLOGY. 28(12), 1371-1378
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
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.
Geoff Lunn (2013- current), Thermal spraying on composite materials, jointly with Prof. Graham McCartney
This is an industrial CASE project with The Welding Institute (TWI), Cambridge, England
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.
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.
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.