PhD on Characterization and optimization of powders produced from sustainable recycled feedstock.

Eindhoven University of Technology is an internationally top-ranking university in the Netherlands that combines scientific curiosity with a hands-on attitude. Our spirit of collaboration translates into an open culture and a top-five position in collaborating with advanced industries. Fundamental knowledge enables us to design solutions for the highly complex problems of today and tomorrow.

The Department of Mechanical Engineering department conducts world-class research aligned with the technological interests of the high-tech industry in the Netherlands, with a focus on the Brainport region. Our goal is to produce engineers who are both scientifically educated and application-driven by providing a balanced education and research program that combines fundamental and application aspects. We equip our graduates with practical and theoretical expertise, preparing them optimally for future challenges.

Introduction

Join a pioneering project focused on sustainable manufacturing: turn scrap steel into valuable metal powders for the future of 3D printing and reduce the environmental impact of the steel industry!

Job Description

Project description

As the steel industry faces urgent climate goals and rising CO₂ taxes, the need to recycle and reuse materials has never been greater. One promising path? Transforming scrap steel into high-value powders for 3D metal printing. This PhD project will contribute to a future where steel is reused locally and efficiently by cutting waste, lowering costs and enabling sustainable manufacturing.

You’ll develop a Computational Fluid Dynamics (CFD) model to simulate the atomization process, where molten scrap steel is broken into tiny droplets and cooled into spherical powders—perfect for additive manufacturing (AM). This model will help predict how scrap steel can be converted into consistent, high-quality metal powders—without relying on expensive, energy-intensive trial-and-error methods.

This PhD project is part of the National Growth Fund program Groeien met Groen Staal (GGS) program GGS program. One of the objectives of Theme Recovery is to promote circularity by reusing scrap metal for the same or similar applications, rather than smelting it down to produce new steel. You'll work at the intersection of fluid dynamics, heat transfer, and material processing. You will collaborate closely with industrial partner Space XYZ and leading researchers at TU Delft to design more efficient and sustainable powder production systems.

The appointed researcher will develop a computational model for the gas atomization of molten scrap steel. This includes simulating primary and secondary breakup phenomena, resolving the turbulent flow fields and droplet formation mechanisms that govern the transformation of molten steel into fine powder. Special attention will be paid to phase change dynamics, particularly the solidification of droplets, which is critical to controlling the quality of the resulting powder.

A key milestone will be the integration of thermophysical properties of scrap steel into the model to ensure accurate thermal behavior and droplet dynamics. As the project progresses, the researcher will work closely with industrial partners to ensure the model reflects the real-world parameters and operating conditions of the demonstrator plant at Space XYZ.

Another crucial element of the project is the co-development of a benchmark in collaboration with Space XYZ and TU Delft. This benchmark will be used to assess and compare model predictions with experimental data such as particle size distributions. Findings will be disseminated through scientific publications and conference presentations.

Key Responsibilities:

• Develop and implement a CFD model for gas atomization of molten metals with a focus on scrap steel
• Simulate the secondary breakup process, incorporating fluid-structure interactions and phase change phenomena
• Model droplet solidification, accounting for material properties and cooling rates specific to scrap steel
• Analyze and validate simulation outputs with experimental data from the industrial demonstrator at Space XYZ
• Collaborate with academic and industrial partners, including TU Delft and Space XYZ, to develop a benchmark for validating model predictions against powder quality and particle size distributions

Why Join Us?

This PhD offers a unique opportunity to work on cutting-edge research that impacts industries such as additive manufacturing, steelmaking and energy storage. You will gain access to state-of-the-art experimental and computational facilities and contribute to sustainable, innovative manufacturing technologies. At TU/e, we’re committed to fostering your professional development, offering you high-quality training programs and a supportive work environment.

We are looking for a talented researcher with a strong background in fluid dynamics, heat transfer and CFD modeling. Experience with multiphase flow simulations and Open Foam will be an asset as you work to develop cutting-edge models for a sustainable industry.

Project team

You will work with a dynamic team of experts, including Dr. Giulia Finotello, Dr. Joris Remmers and Prof. Niels Deen. The research interests of Giulia Finotello include the development of advanced experimental techniques and numerical tools to investigate spraying dynamics.

We are looking for an ambitious PhD candidate to join the exciting and collaborative research project part of the National Growth Fund-Growth with Green Steel (GGS) program GGS program. You’ll work at the forefront of steel powder production, developing innovative, sustainable solutions for the steel industry in collaboration with Space XYZ and TU Delft. Space XYZ runs a demonstrator that atomizes scrap steel and will test your model predictions. At TU Delft, another PhD candidate will perform the additive manufacturing of the powder and collaborate on benchmarking material performance.

Moreover, you will become an active member of the Eindhoven Institute for Renewable Energy Systems EIRES!

Job Requirements

Talented, enthusiastic candidates with excellent analytical and communication skills holding a master’s degree in mechanical engineering, chemical engineering or related fields are encouraged to apply. The following skillsets are required:

• Strong background in fluid dynamics, heat transfer, and computational modeling (CFD) with a proven particle/flow simulation experience in multiphase flows
• Experience with Open Foam is beneficial
• Ability to collaborate within a multidisciplinary research team
• Fluent in spoken and written English.

Conditions of Employment

• A meaningful job in a dynamic and ambitious university, in an interdisciplinary setting and within an international network. You will work on a beautiful, green campus within walking distance of the central train station. In addition, we offer you: 
• Full-time employment for four years, with an intermediate assessment after nine months. You will spend a minimum of 10% of your four-year employment on teaching tasks, with a maximum of 15% per year of your employment. 
• Salary and benefits (such as a pension scheme, paid pregnancy and maternity leave, partially paid parental leave) in accordance with the Collective Labour Agreement for Dutch Universities, scale P (min. € 2,901 max. € 3,707).  
• A year-end bonus of 8.3% and annual vacation pay of 8%. 
• High-quality training programs and other support to grow into a self-aware, autonomous scientific researcher. At TU/e we challenge you to take charge of your own learning process. 
• An excellent technical infrastructure, on-campus children's day care and sports facilities.  
• An allowance for commuting, working from home and internet costs. 
• A Staff Immigration Team and a tax compensation scheme (the 30% facility) for international candidates. 

Information

Do you recognize yourself in this profile and would you like to know more? Please contact the hiring manager, Giulia Finotello, Assistant Professor, [email protected].

Visit our website for more information about the application process or the conditions of employment. You can also contact [email protected] or +31 40 2475902.

Are you inspired and would like to know more about working at TU/e? Please visit our career page.

Application

We invite you to submit a complete application by using the apply button. The application should include a:

• Cover letter in which you describe your motivation and qualifications for the position.
• Curriculum vitae, including a list of your publications and the contact information of three references.
• Brief description of your MSc thesis. 

We look forward to receiving your application and will screen it as soon as possible. The vacancy will remain open until the position is filled.