Electrophysical remanufacturing of aerospace gas turbine components for performance restoration and critical material safeguarding

This exciting opportunity is based within the Advanced Manufacturing Technology research group in the Faculty of Engineering which conducts cutting edge research into sustainable high-value manufacturing processes.

Vision

We are looking for a PhD student who is motivated to develop the next generation of manufacturing processes alongside our partners in Rolls-Royce. Aviation faces a dual challenge: decarbonisation and growing vulnerability in critical raw material supply chains. High-temperature aerospace components rely on exotic alloys and coatings with high embodied carbon and zero domestic supply, yet these components degrade in service.

This PhD project is driven by a vision of extending the life, performance, and value of existing aerospace assets, reducing reliance on virgin critical materials and enabling more sustainable and circular manufacturing practices within the aerospace sector.

Motivation 

For aerospace gas turbines most emissions occur during operation, but the materials used to manufacture critical components also carry a significant environmental and strategic burden. During service components such as blades, guide vanes, and compressors are damaged by calcia–magnesia–alumino–silicate (CMAS) ingress, which degrades thermal barrier coatings and limits component life.

Current recoating and preventative coating methods are effective at a bulk level but struggle to preserve or restore small-scale engineered features that are essential for thermal and aerodynamic performance. This creates a strong need for precision, adaptable, and scalable reconditioning approaches that go beyond conventional manufacturing routes.

Aim

The aim of this PhD is to develop and understand non-conventional electrophysical and laser-based manufacturing processes for the restoration and remanufacturing of aerospace gas turbine components.

The project will:

• Investigate fundamental process–material interactions between coatings, substrates, and electrophysical/laser processes
• Explore process-specific phenomena - including plasma effects - to enable highly localised material removal and deposition
• Develop best-practice methodologies for restoring or enhancing small-scale functional features
• Translate findings towards scalable and deployable solutions with miniaturised, on-wing demonstration

The research will be conducted in close collaboration with Rolls-Royce and will directly inform industrial practice in component repair and life-extension.

Candidate requirements

We are seeking a highly motivated and curious PhD candidate with a strong interest in advanced manufacturing, materials, and sustainability. You should have or expect to obtain a good first degree (1st or a 2:1) in a relevant discipline such as:

• Mechanical engineering
• Manufacturing engineering
• Materials science/metallurgy

The ideal candidate will:

• Enjoy hands-on research
• Be interested in non-conventional manufacturing processes e.g. EDM, laser processing, coatings
• Be motivated by industry-focused research with real-world impact
• Be comfortable working at the interface of academia and industry

You will join a supportive supervisory team spanning academic and industrial expertise with access to specialist equipment including EDM and laser systems and strong links to Rolls-Royce and university spin-outs.

Eligibility and funding

This studentship is open to UK/home and international candidates. 

After a suitable candidate is found, funding is sought from the University of Nottingham as part of a competitive process. This will cover home tuition fees and UKRI stipend.

PhD start date: October 2026

How to apply

Application deadline: 9 March 2026

Please email Alistair Speidel for further questions and to apply for this opportunity via alistair.speidel@nottingham.ac.uk 

The University of Nottingham actively supports equality, diversity and inclusion and encourages applications from all sections of society. We - the Faculty of Engineering - provide a thriving working environment for all our postgraduate researchers (PGRs) creating a strong sense of community across research disciplines. We understand that research culture is important to our PGRs so we work closely with our Postgraduate Engineering Society and PGR research group representatives to support and enhance the postgraduate research environment.

As a PGR at the University of Nottingham you will benefit from training through our Researcher Academy’s training programme. Based within the Faculty of Engineering you will have additional access to courses developed specifically for our engineering and architecture PGRs including sessions on how to write a paper, communicating your research, and research integrity. 

We offer dedicated postgraduate study spaces, have outstanding research facilities and work in partnership with leading industrial partners.