Rocco Lupoi
Assistant Professor, Mechanical & Manuf. Eng
Biography
Dr. Rocco Lupoi was appointed Assistant Professor within the Mechanical & Manufacturing Engineering Department, Trinity College Dublin, in July 2012; the year after he was awarded of a prestigious Marie Curie Fellowship. He is a mechanical engineer by background, obtaining an MEng degree from Politecnico di Torino (Italy) in July 2004 over a "vecchio-ordinamento" course of studies. In the same year he was awarded of a grant for a PhD programme in the University of Bath (UK), with thesis title "Effect of shape, size and material on energy dissipation in Equal Channel Angular Extrusion". In this challenging work, he investigated the concepts and working mechanisms of a novel technology known as UREAD capable of dissipating energy in engineering systems against the occurrence of unwanted events (such as earthquakes, crashes and collisions) and with the potential of being 100% re-usable. After being awarded of a PhD degree in October 2008, he was appointed Research Associate in the Institute of Manufacturing (IfM) - Cambridge University (UK) to explore innovative melting-free material additive processes. He is a recognized expert of Cold Spray and other deposition methods, and he is one of the inventors of a new LASER-based coating technology known as "SprayLaze". He is a major contributor in the field, with high-rank publications, patents submitted and an article in a Nature Publishing Group - NPG journal. Dr. Lupoi in Trinity is exploring new manufacturing processes to include Cold Spray and Selective Laser Melting; he is the lead PI of a large research project in this topic funded by the European Space Agency. Dr. Lupoi is a Funded Investigator of AMBER and I-Form which are SFI research centres. Lectured modules within the School of Engineering are 1MEMS1 - Introduction to Manufacturing (1st year); 5MEMS2 - Advanced Manufacturing (4th year and Master level); 5MEMS1 - Advanced Manufacturing II (Master level).
Publications and Further Research Outputs
Peer-Reviewed Publications
Shuo Yin, Wenya Li, Bo Song, Xingchen Yan, Min Kuang, Yaxin Xu, Kui Wen, Rocco Lupoi, Deposition of FeCoNiCrMn high entropy alloy (HEA) coating via cold spraying, Journal of Materials Science &Technology, 2019
Xingchen Yan, Qing Li, Shuo Yin, Ziyu Chen, Richard Jenkins, Chaoyue Chen, Jiang Wang, Wenyou Ma, Rodolphe Bolot, Rocco Lupoi, Zhongming Ren Hanlin Liao, Min Liu, Mechanical and in vitro study of an isotropic Ti6Al4V lattice structure fabricated using selective laser melting, Journal of Alloys and Compounds, 782, 2019, p209 - 223
Richard Jenkins, Barry Aldwell, Shuo Yin, Subhash Chandra, Gary Morgan, Rocco Lupoi, Solid State Additive Manufacture of Highly-Reflective Al Coatings Using Cold Spray, Optics & Laser Technology, 115, 2019, p251 - 256
Michele Calandri, Shuo Yin, Barry Aldwell, Flaviana Calignano, Rocco Lupoi and Daniele Ugues , Texture and Microstructural Features at Different Length Scales in Inconel 718 Produced by Selective Laser Melting, Materials, 12, (8), 2019, p2 - 32
Nanostructured Metal Coatings via Cold Spray in, Advanced Nanomaterials and Coatings by Thermal Spray, Elsevier, 2019, [S. Yin, C. Chen and R. Lupoi]
H. Shipley, D. McDonnell, M. Culleton, R. Coull, R. Lupoi, G. O'Donnell, D. Trimble, Optimisation of Process Parameters to Address Fundamental Challenges during Selective Laser Melting of Ti-6Al-4V: A Review, Journal of Machine Tools and Manufacture, 2018, p1-10
Shuo Yin, Chaoyue Chen, Xingchen Yan, Xiaohua Feng, Richard Jenkins, Peter O'Reilly, Min Liu, Hua Li, Rocco Lupoi, Significant influence of aging temperature and aging time on the mechanical and tribological properties of selective laser melted maraging 18Ni-300 steel, Additive Manufacturing, 22, 2018, p592 - 600
Aoife Geraghty, Rocco Lupoi, Barry Aldwell, The Bespoke Manufacture of Energy Absorbing Materials Through Additive Manufacturing, 35th International Manufacturing Conference, Dublin Institute of Technology, 20 June 2018, 2018
Shuo Yin, Pasquale Cavaliere, Barry Aldwell, Richard Jenkins, Hanlin Liao, Wenya Li, Rocco Lupoi, Cold spray additive manufacturing and repair: fundamentals and applications, Additive Manufacturing, 21, 2018, p628 - 650
Barry Aldwell, Ben Hunter, Richard Jenkins, Rocco Lupoi, Fundamental Investigation into the Effects of In-process Heat Treatment in Cold Spray, International Thermal Spray Conference 2018, 7-10 May 2018, 2018, pp227 - 232
Barry Aldwell, Ben Hunter, Richard Jenkins, Rocco Lupoi, Fundamental Investigation into the Effects of In-process Heat Treatment in Cold Spray, ITSC 2018-Proceedings of the International Thermal Spray Conference, Orlando (US), May 7-10, ASM International, 2018, pp227 - 232
Xinkun Suo, Shuo Yin, Hua Li, Rocco Lupoi, Deposition and bonding behaviour of cold sprayed porous WC-17CNumerical and Experimental Investigation on Bonding Behavior of Cold Sprayed Porous WC-17Co Particles onto Different Substrates, Coatings, 8, (10), 2018
Shuo Yin, Chaoyue Chen, Rocco Lupoi, Cold Spray additive manufacturing of Al/diamond composites using core-shell structured diamond, ITSC 2018-Proceedings of the International Thermal Spray Conference, Orlando (US), May 7-10, ASM International, 2018, pp202 - 209
M. Meyer, F. Caruso, R. Lupoi, Particle velocity and dispersion of high Stokes number particles by PTV measurements inside a transparent supersonic Cold Spray nozzle, International Journal of Multiphase Flow, (106), 2018, p296 - 310
Shuo Yin, Chaoyue Chen, Xinkun Suo and Rocco Lupoi, Cold Sprayed Metal Coatings with Nanostructure, Advances in Materials Science and Engineering, 2018
Richard Jenkins, Shuo Yin, Barry Aldwell, Rocco Lupoi, Manufacture of Reflective Aluminium Surfaces Using Cold Spray, ITSC 2018-Proceedings of the International Thermal Spray Conference, Orlando (US), May 7-10, ASM International, 2018, pp574 - 580
Xingchen Yan, Shuo Yin, Chaoyue Chen, Chunjie Huang, Rodolphe Bolot, Rocco Lupoi, Min Kuang, Wenyou Ma, Christian Coddet, Hanlin Liao Min Liu, Effect of heat treatment on the phase transformation and mechanical properties of Ti6Al4V fabricated by selective laser melting, Journal of Alloys and Compounds, 764, 2018, p1056 - 1071
R. Lupoi, T. Lupton, R. Jenkins, A.J. Robinson, G.E. O'Donnell, Direct manufacturing of diamond composite coatings onto silicon wafers and heat transfer performance, CIRP Annals - Manufacturing Technology, 67, (1), 2018, p185 - 188
Shuo Yin, Jan Cizek, Rocco Lupoi, New Insights into the Formation Mechanism of Intertwining Interfaces in Cold Spray, ITSC 2018-Proceedings of the International Thermal Spray Conference, Orlando (US), May 7-10, ASM International, 2018, pp219 - 226
Shuo Yin, Xingchen Yan, Chaoyue Chen, Richard Jenkins, Min Liu, Rocco Lupoi, Hybrid additive manufacturing of Al-Ti6Al4V functionally graded materials with selective laser melting and cold spraying, Journal of Materials Processing Technology, 255, 2018, p650 - 655
F. Caruso, M.C. Meyer, R. Lupoi, Three dimensional numerical simulations of the particle loading e ect on gas ow features for low pressure cold spray applications, Surface and Coating Technology, 339, 2018, p181 - 190
Yingchun Xie, Shuo Yin , Jan Cizek, Jan Cupera, Enyu Guo, Rocco Lupoi, Formation mechanism and microstructure characterization of nickel-aluminum intertwining interface in cold spray, Surface and Coating Technology, 337, 2018, p447 - 452
Richard Jenkins, Shuo Yin, Barry Aldwell, Rocco Lupoi, Manufacture of Reflective Aluminium Surfaces Using Cold Spray, International Thermal Spray Conference 2018, 7-10 May 2018, 2018, pp574 - 580
Shuo Yin, Richard Jenkins, Xingchen Yan, Rocco Lupoi, Microstructure and mechanical anisotropy of additively manufactured cold spray copper deposits, Materials Science & Engineering A, 734, 2018, p67 - 76
Richard Jenkins, Shuo Yin, Barry Aldwell, Morten Meyer, Rocco Lupoi, New insights into the in-process densification mechanism of cold spray Al coatings: Low deposition efficiency induced densification, Journal of Materials Science & Technology, 35, (3), 2018, p427 - 431
Shuo Yin, Emmanuel J. Ekoi, Thomas L. Lupton, Denis P. Dowling, Rocco Lupoi, Cold spraying of WC-Co-Ni coatings using porous WC-17Co powders: Formation mechanism, microstructure characterization and tribological performance, Materials & Design, 126, 2017, p305 - 313
S. Yin, T. Lupton, M. Meyer, R. Lupoi, Cold spraying of WC-Co-Ni coatings using porous WC-17Co powders, International Thermal Spray Conference (ITSC), Dusseldorf, Germany, 6-9 June 2017, 2017, pp761 - 765
Barry Aldwell, Daniel Trimble, Shuo Yin and Rocco Lupoi, Enabling diamond deposition with Cold Spray through the coated particle method, Materials Science Forum, 879, 2017, p1194 - 1199
Wenya Lia, Kang Yang, Shuo Yin, Xiawei Yang, Yaxin Xu, Rocco Lupoi, Solid-state additive manufacturing and repairing by cold spraying: A review, Journal of Materials Science & Technology, 34, (3), 2017, p440 - 457
M. Meyer, F. Caruso, R. Lupoi, Nozzle-internal particle velocity measurements and loading effect on particle acceleration inside a Cold Spray nozzle, International Thermal Spray Conference (ITSC), Dusseldorf, Germany, 6-9 June 2017, 2017, pp214 - 220
Cold spray additive manufacture and component restoration in, editor(s)Prof. Pasquale Cavaliere , Cold-Spray Coatings Recent Trends and Future perspectives, Springer, 2017, [S.Yin, B.Aldwell, R.Lupoi]
Shuo Yin, Yingchun Xie, Jan Cizek, Emmanuel Ekoi, Tanvir Hussain, Denis Dowling, Rocco Lupoi, Advanced diamond-reinforced metal matrix composites via cold spray: Properties and deposition mechanism, Composites Part B: Engineering, 113, 2017, p44 - 54
C. de Brún, R. Jenkins, T. Lupton, R. Lupoi, R. Kempers, A.J. Robinson, Confined Jet Array Impingement Boiling, Experimental Thermal and Fluid Science, 86, 2017, p224 - 234
M.Meyer, S.Yin and R.Lupoi, Particle In-Flight Velocity and Dispersion Measurements at Increasing Particle Feed Rates in Cold Spray, Journal of Thermal Spray Technology, 26, (1), 2017, p60 - 70
Shuo Yin, Zhao Zhang, Emmanuel J. Ekoi, Jing Jing Wang, Denis P. Dowling, Valeria Nicolosi, Rocco Lupoi, Novel cold spray for fabricating graphene-reinforced metal matrix composites, Materials Letters, 196, 2017, p172 - 175
L. Armstrong, S. O'Hare, D. Glasgow, R. McCabe and R. Lupoi, Development of Cost Effective Production Improvements within an engineering production environment, 34th International Manufacturing Conference (IMC34), IT Sligo (Ireland), 30-31 August 2017, 2017, pp1 - 8
Thomas L. Lupton, Anthony J. Robinson, Rocco Lupoi, Cold Sprayed Boiling Enhancement Coating, Therminic 2017, Amsterdam, 27-29 September 2017, 2017, pp1 - 4
Barry Aldwell, Elaine Kelly, Ronan Wall, Andrea Amaldi, Garret E. O'Donnell, Rocco Lupoi, Machinability of Al 6061 Deposited with Cold Spray Additive Manufacturing, Journal of Thermal Spray Technology, 26, (7), 2017, p1573 - 1584
R. Lupoi, C. Stenson, K. A. McDonnell, D.P. Dowling, E. Ahearne , Antifouling coatings made with Cold Spray onto polymers: process characterization , CIRP Annals - Manufacturing Technology, 65, (1), 2016, p545 - 548
Shuo Yin, Morten Meyer, Wenya Li, Hanlin Liao, and Rocco Lupoi, Gas Flow, Particle Acceleration, and Heat Transfer in Cold Spraying, Journal of Thermal Spray Technology, 25, (5), 2016, p874 - 896
Chaoyue Chen, Yingchun Xie, Shuo Yin, Marie-Pierre Planche, Sihao Deng, Rocco Lupoi, Hanlin Liao, Evaluation of the interfacial bonding between particles and substrate in angular cold spray, Materials Letters, 173, 2016, p76 - 79
C. Stenson, K. A. McDonnell, S. Yin, B. Aldwell, M. Meyer, D.P. Dowling and R. Lupoi, Cold Spray deposition to prevent fouling of polymer surfaces, Surface Engineering, 2016, p1 - 11
Ildiko Peter, Barry Aldwell, Rocco Lupoi, Mario Rosso, The deposition of pure aluminium via cold spray for the corrosion protection of steel, International Thermal Spray Conference (ITSC), 324, 2016, pp962 - 967
G. Benenati and R. Lupoi, Development of a deposition strategy in Cold Spray for Additive Manufacturing to minimize residual stresses, Procedia CIRP, 55, 2016, p101 - 108
M. Meyer, S. Yin and R. Lupoi, Particle in-flight velocity and dispersion measurements at increasing particle feed rates in Cold Spray, International Thermal Spray Conference (ITSC), 324, 2016, pp37 - 42
M.C. Meyer, S. Yin, K.A. McDonnell, O. Stier, R. Lupoi, Feed rate effect on particulate acceleration in Cold Spray under low stagnation pressure conditions, Surface and Coatings Technology, 304, 2016, p237 - 245
Shuo Yin, Barry Aldwell and Rocco Lupoi, Advanced diamond-reinforced copper composite coatings via cold spray and material characterization, International Thermal Spray Conference (ITSC), 324, 2016, pp305 - 309
Yingchun Xie, Shuo Yin, Chaoyue Chen, Marie-Pierre Planche, Hanlin Liao, Rocco Lupoi, New insights into the coating/substrate interfacial bonding mechanism in cold spray, Scripta Materialia, 125, 2016, p1 - 4
Barry Aldwell, Shuo Yin, Kevin A. McDonnell, Daniel Trimble, Tanvir Hussain, Rocco Lupoi, A novel method for metal-diamond composite coating deposition with cold spray and formation mechanism, Scripta Materialia, 115, 2016, p10 - 13
R. Jenkins, R. Lupoi, R. Kempers, A.J. Robinson, Heat Transfer Performance of Boiling Jet Array Impingement on Micro-Grooved Surfaces, Experimental Thermal and Fluid Science, 80, 2016, p293 - 304
R. Jenkins, C. De Brún, R. Kempers, R Lupoi, A. J. Robinson, Thermal-hydraulic performance of convective boiling jet array impingement , 745, 2016, p1 - 10
C. Stenson, M.C. Meyer, B. Twomey and R. Lupoi, Particle speed analysis in CoBlast, Procedia CIRP, 37, 2015, p77 - 82
Cold Spray in, editor(s)Prof. Luc Laperriere; Prof. Gunther Reinhart , CIRP Encyclopedia of Production Engineering, 2015, pp1 - 4, [R. Lupoi]
Shuo Yin, Xinkun Suo, Yingchun Xie, Wenya Li, Rocco Lupoi, Hanlin Liao, Effect of substrate temperature on interfacial bonding for cold spray of Ni onto Cu, Journal of Materials Science, 50, 2015, p7448 - 7457
Fang LUO , Andrew COCKBURN, Martin SPARKES , Rocco LUPOI , Zhi-jun CHEN, William O'NEILL, Jian-hua YAO, Rong LIU, Performance characterization of Ni60-WC coating on steel processed with supersonic laser deposition, Defence Technology, 11, 2015, p35 - 47
Particle Image Velocimetry (PIV) of Cold Spray of particles in supersonic nozzles in, editor(s)K. Kelly and G O'Donnell , Perspectives on Manufacturing, Trinity Centre for Bioengineering, 2015, pp73 - 83, [R. Lupoi]
M.C. Meyer and R. Lupoi, AN ANALYSIS OF THE PARTICULATE FLOW IN COLD SPRAY NOZZLES, Mechanical Sciences, 6, 2015, p127 - 136
R. Bouttier, G. Lopes, L. Clarke and R. Lupoi, UREAD impact behaviour using Non-Newtonian materials, International Journal of Mechanical Engineering and Applications, 3, (4), 2015, p57 - 62
M. Jones, A.Cockburn, R.Lupoi, M.Sparkes, W.O'Neill, Solid-state manufacturing of tungsten deposits onto molybdenum substrates with supersonic laser deposition, Materials Letters, 134, 2014, p295 - 297
Karen Johanna Quintana Cuellar, Harry Mitrogiannopoulos, Daniel Hiller, Daniel Trimble, Rocco Lupoi, Garret O'Donnell, Jose Luis Silveira, Shaun McFadden, A STUDY ON INTERNAL DEFECTS IN FRICTION STIR WELDING OF ALUMINIUM ALLOYS, 31st International Manufacturing Conference (IMC31) , Cork (Ireland), 3rd of September, 2014, pp69 - 74
M.Meyer, R. Lupoi, COMPUTATIONAL PREDICTION OF COLD SPRAY NOZZLE PER-FORMANCE FOR THE DEPOSITION OF TITANIUM, 31st International Manufacturing Conference (IMC31), Cork (Ireland), 3rd of September, 2014, pp107 - 112
R. Lupoi, Current Design and Performance of Cold Spray Nozzles: Experimental and Numerical Observations on Deposition Efficiency and Particle Velocity, Surface Engineering, 30, (5), 2014, p316 - 322
M. Jones, A. Cockburn, M. Sparkes , W. O'Neill and R. Lupoi, Supersonic Laser Deposition of Tungsten, ASME 2014 Manufacturing Science and Engineering Conference (MSEC 2014), Detroit, USA, 9-13 June, 2014, pp1 - 4
F.Luo, A.Cockburn, R.Lupoi, M.Sparkes, Z.Chen and W. O'Neill , Characteristics of Ni60-WC deposited on steel using Supersonic Laser Deposition and performance comparison with Laser Cladding, Surface and Coating Technology, 2014
LUO Fang, Lupoi Rocco, Cockburn Andrew, Sparkes Martin, O'Neill William, YAO Jian-hua, Characteristics of Stellite 6 Deposited by Supersonic Laser Deposition Under Optimized Parameters, JOURNAL OF IRON AND STEEL RESEARCH, INTERNATIONAL, 20, (2), 2013, p52 - 57
M.Bray, R. Lupoi, A. Cockburn, W. O'Neill, M. Sparkes, Deposition of Coatings on Substrates, 2013, WO 2013/061085
R.Lupoi, A.Cockburn, C. Bryan, M. Sparkes, F.Luo and W.O'Neill , Hardfacing steel with nanostructured coatings of Stellite-6 by Supersonic Laser Deposition, Light: Science & Applications, 1, (1), 2012, p1 - 6
A.Cockburn, R.Lupoi, M.Sparkes and W.O'Neill , Supersonic Laser Deposition of corrosion and wear resistant materials, 37th MATADOR International Conference, Manchester (UK), 2012
F.Luo, A.Cockburn, R.Lupoi, M. Sparkes, W.O'Neill, Performance comparison of Stellite 6 deposited on steel using supersonic laser deposition and laser cladding, Surface and Coating Technology, 212, 2012, p119 - 127
F. Osman and R.Lupoi , Application of UREAD for the energy dissipation in engineering structures, 4th international conference of Advanced Design and Manufacture (ADM), Kunming (China), 2011
R. Lupoi, A. Cockburn, M. Sparkes, C. Bryan, F. Luo and W. O'Neill , Hardfacing engineering surfaces with Supersonic Laser Deposition of Stellite-6, International Congress on Applications of Lasers & Electro-Optics (ICALEO), Orlando (US), 2011, pp345 - 441
R.Lupoi, M.Sparkes, A.Cockburn and W. O'Neill , High speed titanium coating by Supersonic Laser Deposition, Materials Letters, 65, 2011, p3205 - 3207
R.Lupoi and W. O'Neill, Powder stream characteristics in cold spray nozzles, Surface and Coating Technology, 206, (6), 2011, p1069 - 1076
A. Cockburn, R. Lupoi, M. Sparkes and W. O' Neill , Supersonic laser deposition of corrosion and wear resistant materials, 2nd EPRI conference, Oralndo (US), 2011
R. Lupoi and W.O' Neill , An investigation on powder stream in Cold Gas Spray (CGS) nozzles, CFD-ECCOMAS , Lisbon (Portugal), 2011, pp1 - 12
F.Osman and R.Lupoi , Application of UREAD for the energy dissipation in engineering structures, Key-Engineering Materials, 486, 2011, p1 - 4
Computational and Strain Gradient Plasticity in, editor(s)Akhtar S. Khan and Babak Farrokh , Finite Plasticity and Visco-plasticity of Conventional and Emerging Materials, Maryland (US), Neat Press, 2010, pp259 - 261, [R.Lupoi and F.Osman]
F.Osman and R.Lupoi , Application of plastic deformation in a novel re-usable energy dissipation device, PLASTICITY, St. Kitts and Nevis (Caibbean), 2010
M. Bray, A. Cockburn, M. Sparkes, R. Lupoi, W.O' Neill, Supersonic laser deposition of Ti and Ti64 alloys, ICALEO 2010 conference, Anaheim (California, US), 2010
R.Lupoi and W. O'Neill, Deposition of metallic coatings on polymer surfaces using cold spray, Surface and Coating Technology, 205, (7), 2010, p2167 - 2173
R.Lupoi and F.Osman , Loading behaviour of 900 'UREAD' energy channels, International Journal of Crashworthiness, 13, (2), 2008, p195 - 203
R.Lupoi and F.Osman , Investigation into channel angular extrusion and the UREAD energy absorption technique, International Journal of Mechanical Sciences , 50, (5), 2008, p966 - 973
R.Lupoi and F.Osman , Analysis of tool cavity stresses in channel angular extrusion, Key-Engineering Materials, 340-341, 2007, p1381 - 1386
R.Lupoi and F.Osman, Characterization of a single 90-degrees 'UREAD' energy channel, ICRASH 2006, Athens (Greece), 2006
R.Lupoi and F.Osman, Characterization of a single 90-degrees 'UREAD' energy channel, ICRASH 2006, Athens (Greece), 2006, pp1 - 10
F.Osman and R.Lupoi, Analysis of tool cavity stresses in channel angular extrusion, AEPA 2006, Nagoya (Japan), 2006, pp1 - 6
R.Lupoi and F.Osman, Use of concealed pressure pins to determinate contact stresses in ring compression, ESAFORM 2005, Cluj-Napoca (Romania), 2005, pp519 - 522
R.Lupoi and F.Osman, A new Approach for experimental evaluation of contact stresses, AMPT 2005, Wisla (Poland), 2005, pp1 - 4
R.Lupoi and F.Osman, Under surface pressure sensing technique for the evaluation of contact stresses, Journal of Material Processing Technology, 164-165, 2005, p1537 - 1543
Non-Peer-Reviewed Publications
M. Meyer and R. Lupoi, Supersonic Spray Advanced Modelling SSAM, 19th Annual Sir Bernard Crossland Symposium & Postgraduate Workshop, Queen's University Belfast, 2016
R.Lupoi and F.Osman, Revolutionary devices to dissipate energy in mechanical systems, PGA 2006 , Bath (UK), 2006
Research Expertise
Description
Additive Manufacturing; Cold Spray; Materials Characterization; Lasers and Material Laser Processing; Friction Welding and Friction Stir Welding; Supersonic flows and applications; Fluid mechanics, Computational Fluid Dynamics (CFD) and applications; Solid Mechanics (Crashworthiness and Energy Absorbers); Components and systems design for engineering applications, product developmentProjects
- Title
- Implementing Additive and Cold Spray Techniques for the smart manufacturing of valve componenTs (IMPACT)
- Summary
- Currently, the Fourth Industrial Revolution, or Industry 4.0, is under way. It is marked by emerging technology breakthroughs in a number of fields, including robotics, artificial intelligence, nanotechnology, quantum computing, biotechnology, 3D printing and autonomous vehicles. As we find ourselves firmly in the 4th industrial revolution, there are at least three major impacts for manufacturing industry emerging: additive manufacturing, energy and resource efficiency, and data. Additive Manufacturing (AM) is in essence the industrialisation of 3D Printing, and we see additively manufactured metal parts becoming more mainstream, for example in aeroengines as GT nozzles, in the field of medical such as hips and knee prosthesis and many other applications. The successful implementation of this project will result in two major impacts: 1. Allowing the company partner to manufacture customized high-end valves with complex structure by SLM at low cost and short production circle. 2. The modification of the valves structure can be achieved without damaging the original body via CS, which significantly reduce the cost by designing and manufacturing a new valve.
- Funding Agency
- Enterprise Ireland (EI)
- Title
- Duplex solid-state surface engineering for novel thermal control coating systems on spacecraft
- Summary
- This research proposal is a collaborative research project between TCD, ENBIO and Cranfield University to develop new surfaces for use in thermal control of surfaces on spacecraft. Thermal control is important on a spacecraft as the on-board instruments need to stay at a consistent temperature, while the outside of the craft is exposed to extreme Solar radiation. Thermal control relies on radiative heat-transfer mechanisms (control the amount of UV light that is absorbed or reflected), and to emit heat in the long wavelength infra-red. New surfaces are developed to increase the stability and lifetime of thermal control coatings, especially for new, smaller spacecraft such as CubeSats. ENBIO's SolarBlack is a char-bone based thermal control coating, already qualified for use in Space on the ESA's Solar Orbiter mission. The project will focus on the thermal & optical aspects of new coating systems under a simulated space environment. The project novelty is the investigation and combination of a range of techniques: metal matrix composites (MMCs), CoBlast and Cold Spray. This combination will produce a surface with novel material performance compared to basic systems. The coating system will be produced by a combination of MMCs coating (fabricated by Cold Spray at TCD) followed by 'SolarBlack' (deposited by CoBlast at ENBIO) on top. Optimised coating system will be applied to spacecraft grade metals and tested by ENBIO and Cranfield University under simulated service conditions. The processing parameters' effect on the material structure and thermo-optic stability of coating systems in extreme environments will be investigated.
- Funding Agency
- Irish Research Council (IRC)
- Title
- Supersonic-assisted laser ablation for the deposition of thin coatings at high rates
- Summary
- Pulsed Laser Deposition (PLD) is widely used to make thin films not amenable to conventional methods, such as thermal evaporation and sputtering. Despite critical technical advantages, PLD presents low deposition rates and currently finds limited applications in industry. In this TIDA we will investigate and assess a new thin film deposition technique (called SALA), based upon PLD principles, but with the potential to deliver high deposition rates and within an atmospheric environment. Laser ablation is used to vapourise the coating material, where it is entrained in a supersonic gas flow and carried at high velocity to a substrate for deposition.
- Funding Agency
- Science Foundation Ireland (SFI)
- Date From
- January 2019
- Date To
- December 2019
- Title
- Novel Hybrid Additive Manufacturing for the Fabrication of Functionally Graded Multi- Materials Components
- Summary
- Functionally graded multi-materials (FGMs) components are characterized by spatially variation of materials or microstructures, resulting in multiple properties and functions at different parts. FGMs are able to gain the best of all constituent materials, having wide applications in the modern industry. Additive manufacture of a near-net-shape FGMs component with fine details is always a challenge work because the welding of incompatible materials results in large residual stress, high porosity and cracks at the multi-materials interface, especially in metals. In this research, the work aims to develop a hybrid additive manufacturing technology combining selective laser melting (SLM) and other emerging techniques to fabricate high-quality FGMs components, currently not possible to be manufactured.
- Funding Agency
- Irish Research Council (IRC)
- Date From
- 2017
- Date To
- 2019
- Title
- Exploring metal-AM and novel 3D printing techniques for the manufacturing of devises in orthopaedics
- Summary
- The background of this programme is directly linked to metal Additive Manufacturing (AM). Techniques that constitute this field, such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM) have shown great progress in recent years. It is now possible to directly 3D print components with complex features and with minimum post-processing operations before reaching the net shape. For example, the typical SLM process would require no tooling, is fully automated, and can manufacture components with multi-features in one single processing step. Metal AM has therefore attracted the interest of several sectors; however it seems particularly well suited for the biomedical industry. Using conventional manufacturing processes, this would require investment casting, complex machining processes, finishing processes coupled with etching and coatings steps to achieve a final product. Using SLM, these manufacturing steps can be reduced significantly.
- Funding Agency
- AMBER and DePuy Ireland
- Date From
- 2017
- Date To
- 2019
- Title
- Development of Cold Spray towards the next generation Additive Manufacturing
- Summary
- Cold Spray (CS) is an innovative coating manufacturing process, which allows for the formation of material layers in a solid-state (free of melting) manner. In this method, the feedstock material (in the form of powder) is injected at the inlet of a converging-diverging supersonic nozzle. The nozzle is fed with high pressure gas (nitrogen or helium), which expands through the internal channel and reaches supersonic speed at the exit (above 1000m/s). Particles are dragged by the fast jet, and upon impact against a substrate material they plastically deform and stay bonded. This project aims at developing a unique CS laboratory facility, the first one in Ireland, for CS applications in Space programmes in the form of coatings and and 3D components made out of composites and metals.
- Funding Agency
- European Space Agency (ESA)
- Date From
- 2014
- Date To
- 2018
- Title
- The technical and commercial development of Cold Spray applications in Ireland - SprayIreland
- Summary
- This is a challenging and high impact project (27 months duration), that will explore and develop commercial applications for Cold Spray. A preliminary feasibility investigation revealed a high implementation potential within the Irish based industry. In close collaboration with a number of industry partners, SprayIreland will develop the technical tools to address, using Cold Spray and similar methods, key challenges within the industry sphere that current technologies have so far failed to solve.
- Funding Agency
- Enterprise Ireland (EI)
- Date From
- 2015
- Date To
- 2017
- Title
- Supersonic Spray Advanced Modelling - SSAM
- Summary
- Current methods for the manufacturing of metallic coatings onto non-metallic surfaces are slow, limited in size and to a small range of feedstock materials. Also, they require time-consuming masking steps or complex etching procedures, have low bond strengths, and are coming under very strong pressure to limit their environmental impact through the elimination of toxic waste products. This project will start investigating a revolutionary powder-based technology which will lead to the device of a mask-free, environmentally friendly and low-cost deposition process tailored to the manufacturing of metallic coatings onto non-metallic components. The deposit formation is completely solid-state (free of melting). This programme, Supersonic Spray Advanced Modelling - SSAM, will generate the required computational tools to study and control the particles acceleration process within the processing nozzle.
- Funding Agency
- FP7 - Marie Curie Actions
- Date From
- 2013
- Date To
- 2017
Recognition
Representations
Journal of Nuclear Materials - Reviewer
Journal of Materials Processing technology - Reviewer
Additive Manufacturing - Reviewer
Journal of Visualized Experiments (JoVE) - Reviewer
Optics and Laser Technology - Reviewer
ASME Journal of Manufacturing Science and Engineering - Reviewer
Journal of Thermal Spray Technology - Reviewer
Fuel Processing Technology - Reviewer
Applied Surface Science - Reviewer
Proposals reviewer for calls by research funding bodies in Ireland, France and Canada
CIRP Journal of Manufacturing Science and Technology - Reviewer
Springer and SpringerPlus - Reviewer
Materials & Design - Reviewer
International Academy for Production Engineering, CIRP-E events - part of Scientific Commitee
Associate Editor for De Gruyter - http://degruyteropen.com/people/rlupoi/
Journal of the Brazilian Society of Mechanical Sciences and Engineering - Reviewer
Surface & Coating Technology - Reviewer
International Journal of Thermal Sciences - Reviewer
Scientific Researach and Essays - Reviewer
Chemical Engineering Science - Reviewer
Awards and Honours
Accelerated Advancement Award
SFI - TIDA award
Enterprise Ireland - Commercialization Fund
European Space Agency (ESA) major grant award, Technology Research Programme (TRP)
Irish Research Council - New Foundation Award
Marie Curie Fellowship (CIG)
Certificate for professional engineering practice, Chartered Status
Silver medal for professional achievements in the AMPT 2005 conference. Prize given in Wisla, Poland (2005)
A scholarship for PhD studies at the University of Bath
An Erasmus scholarship, Politecnico di Torino (Italy)
Memberships
Committee member on the national standards authority of Ireland (NSAI)
Funded Investigator of I-Form (http://www.i-form.ie/staff.html)
PI of Science and Technology in Advanced Manufacturing (STAM) https://www.tcd.ie/mecheng/research/stam/
Funded Investigator of AMBER - http://ambercentre.ie/
Nominated Associate Member of the International Academy for Production Engineering (CIRP)
Member of the Italian Professional Body for Engineers (Albo degli Ingegneri), Chartered Engineer level
Member of the Irish Manufacturing Council (IMC)
Only member in Ireland of the Cold Spray Society, a group of world leading experts in the field run by the School of Mines in Paris