My research group focuses on surfaces, interfaces and coatings technology for energy applications. My research interest lies in the understanding of novel materials manufacturing processes specifically High Velocity Oxy-Fuel thermal spray, cold gas dynamic spray and laser cladding 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 a member of the Cleaner Fossil Energy and Carbon Capture Technology Research Group and an associate member 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 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.
Current Research Grants
- 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, £74 k, 2015-16, Rolls-Royce Plc (Aerospace)
- High velocity oxy fuel spray for internal surfaces, £33 k, 2015-19, Monitor Coatings Ltd
- Cold spray deposition of precipitation hardenabe Al alloy, £32 k, 2015-19, TWI
- Fe based coatings for application in biomass boilers, £25k, 2014-17, EON Technologies (Ratcliffe) Ltd
- Ceramics for application in power plants, £78 k, 2014-17, Rolls Royce Plc (Nuclear)
- Low pressure cold spray repair of Al 6xxx carriages, £45 k, 2015-16, Bombardier Transport
- Suspension HVOF spray of alumina, £23 k, 2015-16, Wallwork HT Cambridge
- Biomass and Fossil Fuel Research Alliance (BF2RA) funded Development of novel coatings for biomass boilers, £40k, 2012-2015,(Held at Cranfield Uni.)
High Temperature Oxidation of HVOF Thermal Sprayed NiCr-Cr3C2 coatings: Microstructure and Kinetics, Journal of Material Science, 50 (20), 6808- 6821 http://link.springer.com/article/10.1007/s10853-015-9238-z
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), 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).
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.
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
Dr Zdenek Pala, Research Fellow in Energy Materials, (2015- current)
Dr Pala joined us from the Institute of Plasma Physics, Czech and he is currently involved in developing the next generation of thermal and laser cladded coatings for the ultra supercritical fluidized bed power plants. His research focuses on studying high temperature erosion-corrosion. https://scholar.google.com/citations?user=dxlkzI8AAAAJ&hl=ja
Jamie Pulsford, EngD Research Engineer, (2015- current)
Jamie's research focuses on thermal spraying of internal surfaces using the latest generation of HVOF technology for wear and high temperature corrosion resistance.
Gilbert Karimi, PhD student, (2015- current)
Gilbert is studying the degradation of ceramics and hardfacing materials in hydrothermal corrosion for future pressurized water reactors.
Liam Reddy, EngD research engineer, (2014- current)
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.
Bo Song, PhD student, (2013- current)
Bo is developing HVOF, laser cladded and cold sprayed Ni50Cr coatings for heat-exchangers in biomass fired boilers.
Dominika Orlicka, PhD, (2012- 15)
Dominika studied development of novel coating compositions for fireside corrosion protection in biomass fired boilers at Cranfield University. The project was sponsored by BF2RA (Biomass and Fossil Fuel Research Alliance) and co-supervised by EON New Build and Technology, Nottingham. Dominika used a multiple target PVD coater to produce a range of compositions for exposure in a simulated biomass fired combustion environment.
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