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Faculty of Materials Engineering - Scientific research

Research carried out at the Faculty of Materials Engineering and Metallurgy mostly focuses on the following topics: 

  • waste-free technologies,
  • development and utilization of waste materials,
  • mathematical modelling and optimization of metallurgic processes,
  • environment management,
  • electric heating engineering,
  • computer aided design processes,
  • theory and technology of metallic materials,
  • cracking mechanics,
  • biomechanics,
  • modelling of heat flow processes,
  • kinetics of welding processes,
  • waste formation and destruction,
  • technologies of composite formation,
  • surface engineering,
  • founding,
  • structure analysis and properties,
  • design of chemical composition and technologies of materials subjected to complex mechanical and thermal load and corrosion environment,
  • ceramic technologies of special properties,
  • stereological methods,
  • new biomedical materials.

Every year, around 100 research projects are implemented at the Faculty.

In the time period between 2013 and 2016, our workers applied for 15 patents.

 

Department of Production Engineering conducts research activities in the fields of:

  • organization and management of production,
  • lean manufacturing,
  • innovation management,
  • optimization and logistics of supply chain,
  • development of work environment and work safety regulations.

Projects implemented at the Department:

  • research and development of measurement and analysis system for assessment of the level of sound emitted during production of welded structures.
  • research and development of environment-friendly technology using iron-bearing waste materials and waste plastics.
  • production engineering with POWER

 

Main research conducted at the Institute of Metals Technology:

  • in the field of extractive metallurgy:
    • ferrous metallurgy
    • recycling of metals
    • pyrometallurgy of non-ferrous metals
    • hydrometallurgy of non-ferrous metals
    • vacuum metallurgy
  • in the field of foundry:
    • casting technologies for non-ferrous alloys
    • thermal analysis (ATD, DTA)
    • heat treatment of castings
    • optimization of casting technologies
  • in the field of mechanics:
    • determination of mechanical characteristics (e.g. fracture and fatigue)
    • durability evaluation for machine elements and structural components under mechanical and thermal loading
    • mechanical states modelling
    • evaluation of material effort in energetic devices
  • in the field of metal forming:
    • determination of materials formability (plastometric tests)
    • development of unconventional metal-forming methods and devices
    • evaluation of functional properties of metal-formed products
    • physical and mathematical modelling of metal forming processes

Cold crudible oven


Main research projects implemented in the Institute:

  • Modern material technologies in the aerospace industry (PKAero), Innovative Economy Operational Programme (IE OP) No. POIG.01.01.02-00-015/08-00,
    Project coordinator at the Silesian University of Technology: Prof. PhD DSc Eng. Eugeniusz Hadasik, duration: 1.07.2008- 30.06.2015
  • Development of innovative technology for production of significantly improved bends of thick-walled steam pipelines, Innovative Economy Operational Programme (IE OP) No. POIG.01.04.00-24-040/12, Project led by ZRE Katowice S.A.,
    Project coordinator at the Silesian University of Technology: PhD DSc Eng. Marek Cieśla, Prof. in SUT
  • Application of magneto-hydro-dynamic pump to platinum recovery from used autocatalytic converters - Project of the National Science Centre No. N N508 6255 40, Project coordinator: PhD Eng. Agnieszka Fornalczyk
  • Alternative carboniferous materials for technologies of copper production in KGHM Polska Miedź (Cu-RED) – No. PST1/A5/21/2012, duration: 1.11.2012-                31.10.2015
  • Energetic effects accompanying the creation of intermetallic phases from system Al-Zr - Project of the National Science Centre No. UMO-2011/03/N/ST8/03807,
    Project coordinator: MSc. Eng. Tomasz Maciąg; duration: 12.09.2012 - 11.09.2014
  • Innovative technology of processing cords from used tyres to the form of balanced product in metallurgical process, duration: 2015-01-01 – 2017-12-31

 

Main areas of research conducted at the Division of Ceramic Materials and Composites, under the Institute of Material Science, in the field of ceramics:

  • Materials engineering: advanced oxide ceramics, oxynitride ceramics, ceramic phosphors, transparent ceramics, nanocomposites, glass and optic fibres, biomaterials,
  • Advanced technologies in ceramics: ceramic powder processing, mechanochemical processing, solid-state synthesis methods of non-oxides
  • Ceramic technologies in recycling
  • Methods of testing: particle size distribution, erosion and corrosion of ceramics, X-ray structural analysis, scanning electron microscopy, optical properties


Major research projects, currently implemented or recently completed at the Division of Ceramic Materials and Composites (financed from external sources):

  • Preparation and properties of yttrium garnet (YAG) doped with nitrogen and cerium.: 2009-2012. Full Professor Małgorzata Sopicka-Lizer
  • The use of ceramic technology in the processes of recycling and waste disposal. 2008-2011. Full Professor Stanislaw Serkowski.
  • Nanostructured ceramics based on silicon nitride. 2008-2011: Tomasz Pawlik, PhD
  • Removing fibre glass-ceramic preform based on SiO2-Al2O3-PbO-PbF2 doped ions, thulium, ytterbium and erbium for the purpose of active fibres and to determine their ownership of transmission and emission. 2009-2011 Full Professor Michael Żelechower.
  • Preparation and characterization of nitride phosphors obtained by reduction of oxides. 2011-2014, Tomasz Pawlik, PhD
  • Nanostructured composite materials and reinforced ductile iron application, 2011-2014, Full Professor Małgorzata Sopicka-Lizer
  • Preparation and luminescent properties of single phase YAP:RE3+ ceramic materials, 2014-2017, Daniel Michalik, PhD
  • Manufacturing of light ceramic aggregates from waste materials, 2015-2017, Full Professor Małgorzata Sopicka-Lizer
  • A quantitative description of the kinetics of nucleation and crystallization of fluorides and oxyfluorides' nano-crystals in glass fibre and oxide-fluoride co-doped with erbium and ytterbium, as well as luminescent properties of transmission and fibre glass-ceramic. 2015-2017. Full Professor Michael Żelechower.
  • Synthesis of efficient luminophosphors based oxynitride compounds for the lighting industry, 2015-2018, Full Professor Małgorzata Sopicka-Lizer,
  • Characteristics of effects of structural materials like WC-Co modified sub micrometre carbide powders. 2015-2018 Hanna Myalska, MSc

 

Main areas of research conducted at the Division of Heat Treatment and Surface Engineering, under the Institute of Material Science:

  • CVD, out of pack and pack cementation technologies - high temperature resistant coatings for aero-engine, turbine blade and vanes application,
  • High temperature resistant coatings for TiAl alloys,
  • High temperaturę resistant coatings for refractory metal and alloys,
  • Thermal Barrier Coatings (TBC) by Air plasma spray, EB-PVD method,
  • PVD technologies – hard coatings,
  • Corrosion and erosion resistant coatings for aero-engine compressor blades – multilayer coatings, slurry technology,
  • Hard diffusion coatings (boronizing, chromizing),
  • structure and properties of high temperature coatings, isothermal and cyclic oxidation
    tests.


Major research projects, currently implemented or recently completed at the Division of Heat Treatment and Surface Engineering:

  • Development and implementation of MeCrAlY-ZrO2xY2O3 thermal barrier coating (TBC) technology on surface of aviation engine combustion chambers, industrial partner Pratt and Whitney Rzeszow (formerly WSK ”PZL-Rzeszów”). Technology was implemented on combustion chamber of PZL-10W engine.
  • Development and implementation of deposition technology and properties of protective coatings on aircraft engine components, made of nickel and titanium alloys, industrial partner Pratt and Whitney Rzeszow. Technology was implemented on PW 4000 engine components.
  • Implementation of diffusion aluminizing technology for gas turbine blades made of nickel alloys by gas method, industrial partner Pratt and Whitney Rzeszow. Technology was implemented and approved by the NADCAP.
  • Development and implementation of heat-resistant coating technology on surface of integrally cast turbine parts made of IN738 and ŻS6UWI alloy, industrial partner Pratt and Whitney Rzeszow. Technology was implemented for cast apparatus and rotors made of IN738 and ŻS6UWI alloy.
  • Development and implementation of platinum-modified aluminide coatings technology on gas turbine blades, with increased resistance to high temperature corrosion, industrial partner Pratt and Whitney Rzeszow. Technology was implemented on aero-engine turbine blades made of nickel base alloy.
  • Development and implementation of anti-corrosion protection technologies for stationary and rotary components of the PZL-10W and PZL-10S engine compressors using alternative chromium-free coatings, industrial partner Pratt and Whitney Rzeszow. Technology was implemented on aero-engine compressor parts.
  • European Project COST – 522: „POWER GENERATION INTO the 21 CENTURY: “Ultra efficient, low emission plant” Gas Turbine Group, Working Group WP 2, New coatings and processes „Overaluminizing of MeCrAlY coatings by arc-PVD process.”
  • Development of surface hardening technology of inlet portions of the PW 200 engine diffuser ring, industrial partner Pratt and Whitney Canada. Technology was implemented on diffuser part in Pratt and Whitney Rzeszow.
  • Process development and evaluation of hafnium and platinum modified aluminide coatings on nickel base superalloys, work financed by Pratt and Whitney Canada.
  • Development and implementation of technology for regeneration of the top layer of aircraft engine components coated with diffusion aluminide layers and TBC thermal barrier coatings, industrial partner Pratt and Whitney Rzeszow. Technology was implemented on aero-engine compressor parts.
  • Structure shaping and properties of protective coatings obtained on nickel base superalloys used for military turbine components and civil aviation engines, industrial partner Avio Aero Polska. Technology was implemented on aero-engine turbine parts.
  • Base of technology and research of the properties of abrasion and high temperature corrosion resistant coatings on the γ-TiAl alloy, part of NEWAC project, in cooperation with WSK PZL-Rzeszów S.A.
  • Development of technological parameters for diffusion aluminizing process of Inconel 713 LC alloy, industrial partner PBS Velka Bites, Czech Republic.
  • Development and implementation of ceramic and carbide coating technology using TRIPLEX PRO 200 triple torch plasma gun, industrial partner Pratt and Whitney Rzeszow, INNOTECH project.
  • Cooperative Research for Next Generation High Efficiency LP Turbine, Acronym: Coopernik, “Advanced Improved Efficiency Low Pressure Turbine Unit”, industrial partner Avio Aero Polska, INNOLOT project,
  • Advanced techniques of aircraft transmission manufacturing, Acronym: InnoGear, “Advanced Technique of Aircraft Gear Manufacturing”, industrial partner Safran Hispano-Suiza Polska, INNOLOT project.

 

Main areas of research conducted at the Division of Metallography, under the Institute of Material Science:

  • Materials preparation,
  • Metallographic research,
  • Quantitative description of macro- and microstructure of materials,
  • Stereology and implementation of image analysis methods in light and electron microscopy,
  • Application of quantitative materiallography and fractography methods in investigation aimed at determination of quantitative relations in chemical composition-technology-microstructure-properties chain of materials,
  • Computer modelling and quantitative evaluation of microstructure of polycrystalline materials and materials containing dispersed phase particles,
  • Materials and technologies for aviation industry: nickel- and cobalt-base superalloys,
  • Metallic matrix composites,
  • Materials and process selection,
  • Application of statistical methods of experiments and results analysis planning to material research.


Major research projects, currently implemented or recently completed at the Division of Metallography:

  • Modern material technologies applied for aircraft industry: Investment casting of Ni-based superalloys for critical parts of aircraft engines. POIG European project.
    Main researcher: Jan Cwajna. (2009-2014).
  • Elaboration of new super coarse-grained sintered carbides with nickel containing matrix. PBU project.
    Main researcher: Janusz Richter. (2011-2014).
  • Heat treatment optimization for single crystal CMSX-4 nickel-based superalloy. Iuventus Plus project.
    Main researcher: Agnieszka Szczotok. (2010-2012).
  • Modern material technologies applied for aircraft industry: Materials for aircraft with complex structure. POIG European project.
    Main researcher: Jan Cwajna. (2009-2012).
  • Elaboration of technological process of production of components for hot sections of aircraft engines using directional solidification. PBZ project.
    Main researcher: Jan Cwajna. (2007-2010).
  • Materials development conditions of sand casting for new generation of magnesium alloys. PBR project.
    Main researcher: Jan Szala. (2007-2010).
  • Analysis of intersurface interaction of magnesium alloys - carbon in aspect of production possibility of new construction materials. PBU project.
    Main researcher: Anita Olszówka-Myalska. (2007-2010).
  • Elaboration of technological foredesign for pressure die-casting of magnesium alloy - carbon fibres composite. PBR project.
    Main researcher: Anita Olszówka-Myalska. (2010-2013).
  • Role of alloying constituents in processing of connection structure in magnesium alloys - carbon fibres composites. PBU project.
    Main researcher: Anita Olszówka-Myalska (2010-2012).
  • INNOLOT-1-08, INNOCAST „Investment - casting process optimization and validation of hollow LPT multivane clusters with thin walls and trailing edges for GP7000 turbofan jet engines”: WP7 - Post-cast operation, quality control techniques and procedures, WP8 - Validation and optimization of casting repairing proces parameters.
    Main researcher: Jan Cwajna (2013-2015).
  • Advanced casting technologies. INNOLOT project.
    Main researcher: Jan Cwajna (2013-2018).

 

Division of Engineering Materials, operating within the Institute of Material Science, is mainly involved in research connected with the analysis of materials' structure and development of technology.

Fields of interests of the scientific staff comprise of:

  • Fabrication and analysis of microstructure, as well as properties of Ti-Al, Fe-Al and Ni-Al alloys;
  • Microstructure and properties of casting Al and Mg alloys, including die-casting alloys, alloys applied in elevated temperatures and metal matrix composites;
  • Influence of hydrogen on microstructure and properties of structural materials;
  • Materials applied in power generation industry, materials wear and corrosion processes, welding and materials joining technologies;
  • Microstructure and properties of nano- and ultrafine materials, fabricated by severe plastic deformation (SPD) method;
  • X-Ray phase composition analysis (Rietveld’s method and analysis of diffraction pattern);
  • Creep resistance investigation;
  • Recovery and recrystallization process of materials after hot-working;
  • High manganese steels applied in automotive industry;
  • Biomedical materials.


A number of research projects has been conducted at the Department of Engineering Materials:

  • “Fabrication of nano- and ultrafine CuCr and CuFe materials by severe plastic deformation (SPD) methods”,
  • “Development of manufacturing process of monolithic housing for gas insulated switchgears with increased operation parameters”,
  • “Technology of laser welding of finned tubes made out of austenitic steel and Ni alloys applied in supercritical and ultra-supercritical boilers”,
  • “Influence of hydrogen on microstructure and stress corrosion cracking of selected Mg-Y-RE-Zr and Mg-Al-RE alloys”,
  • “Manufacturing of magnesium alloy WE43 metal matrix composites reinforced with ceramic particulates and carbon fibres for application in elevated temperature”,
  • “Phenomena occurring during creep of modern, high-silicon Mg-Si-X (Mn, Sn, Zn) alloys”,

 

Department of Industrial Informatics undertakes research activities in the fields of:

  • Artificial intelligence methods,
  • Computational intelligence,
  • Intelligent modelling of technological processes
  • Electromagnetic processing of materials,
  • Magnetohydrodynamics


Current research projects implemented at the Department (external financing):

  • Development of technologies and computer models for contour induction hardening of complex shape steel components, 2014-2017
  • Development of system solutions supporting crime scene investigation processes on the basis of evidence preserved using laser scanning and satellite measuring techniques, 2015-2017
  • Control and optimization of technological processes using artificial intelligence methods. BK, 2013-2017
Scholarships 2020/2021
Admission 2019/2020
Art & Design Competition
European projects
ELSEVIER Awards Poland
HR Excellence in Research
 
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