Master's thesis: Microstructure Optimisation of Metal Binder Jetting Components Through Sintering and Rapid Cooling Treatments

Master's thesis: Microstructure Optimisation of Metal Binder Jetting Components Through Sintering and Rapid Cooling Treatments

Introduction
We are seeking a student with a background in materials science or an equivalent discipline, with emphasis on characterisation techniques. Knowledge of metallic materials, sintering principles, and additive manufacturing is desired for this thesis project.

Purpose and Aim
Metal Binder Jetting (MBJ) has emerged as a promising additive manufacturing technique due to its high productivity, design freedom, and suitability for complex geometries. Unlike fusion-based technologies, MBJ produces parts through a two-stage process involving powder deposition/binder printing followed by thermal post-processing. As a result, the final microstructure is strongly influenced by sintering conditions, heating and cooling rates, part density evolution, and potential secondary heat-treatment steps.

For high-alloy and high-carbon steels, sintering behaviour is particularly critical. Improper heat treatment can lead to undesired phase distributions, excessive grain growth, or carbide precipitation. To address these challenges, this project will investigate sintering optimisation routes and explore Hot Isostatic Pressing (HIP) in ultra-rapid quenching (URQ) mode. By applying different cooling rates, we aim to better understand microstructure evolution and correlate it with hardness and expected mechanical performance.

The overarching goal of this master's thesis is to characterise and optimise the microstructure of MBJ-produced components through tailored sintering conditions and controlled cooling strategies. The project will establish how thermal processing parameters influence phase formation, grain structure, densification, and precipitation behaviour.

Research Questions

• How does the microstructure evolve after sintering under different temperatures, dwell times, and atmospheres?

– Phase transformations, grain growth, densification, precipitation behaviour, and pore evolution.

• How do HIP Ultra Rapid Quenching (URQ) conditions and varying cooling rates influence the final microstructure?

– Retained phases, carbide formation, suppression of grain coarsening, and resulting hardness.

• What combination of sintering and cooling strategies yields the most desirable microstructural state for high hardness and good mechanical performance?

Methodology and Experimental Work
The work will require comprehensive microstructure characterisation using:

• Light Optical Microscopy (LOM)
• Scanning Electron Microscopy (SEM) with EBSD for grain orientation and phase mapping
• X-ray Diffraction (XRD) for phase identification and quantification.
• Hardness testing and density measurements.

Thermal processing will involve:

• Sintering trials at varying temperatures, dwell times, and cooling schedules.
• HIP treatment in URQ mode.
• Controlled cooling experiments (slow, moderate, rapid quenching).

By combining these techniques, the project will establish clear structure–process relationships for MBJ components and provide scientifically grounded recommendations for optimised sintering and post-processing treatments.

Qualifications
We are seeking one student enrolled in master's programme in Materials Engineering or have taken courses like Additive manufacturing or Phase transformations.

Terms
Compensation:
For an approved thesis project worth 30 credits, we pay a compensation of

Time frame:
The thesis covers 30 credits/20 weeks and begins mid-January 2026. This work is suitable for one student.

Location:
This project will be performed at the Department of Physics at Chalmers University of Technology in close cooperation with the Additive Manufacturing Unit at Research Institutes of Sweden RISE AB, Mölndal.

Further questions and how to apply:
Please send your application, including your CV, no later than January 6th, 2026. If you have any questions, please contact , or

Welcome with your application