Dr Nick Weston

MEng, PhD, MIMMM

School of Chemical, Materials and Biological Engineering

Application Scientist (Advanced Metals Processing) | Henry Royce Institute

n.weston@sheffield.ac.uk

Royce Discovery Centre

Full contact details

Dr Nick Weston
School of Chemical, Materials and Biological Engineering
Royce Discovery Centre
5 Portobello Street
Sheffield
S1 4ND

Profile

Nick joined the Henry Royce Institute in October 2022 as an Application Scientist, bringing a strong background in advanced metals processing and powder metallurgy. He completed his undergraduate degree in Aerospace Engineering and a PhD in Metallurgy, both at The University of Sheffield. Followed by 6 years as a Postdoctoral Research Associate (PDRA) in the Sheffield Titanium Alloy Research (STAR) group.

Nick focuses on developing capabilities and understanding limitations of Field Assisted Sintering Technology in order to apply its unique processing potential to solve real-world industrial manufacturing problems. Previous research included recycling waste titanium alloys through the FAST and FAST-forge processes to produce affordable engine components for the automotive industry (FAST STEP 3). This work has been featured as a case study for the Henry Royce Institute.

Qualifications

Oct 2022 – Present: Henry Royce Institute Application Scientist (Advanced Metals Processing).
Oct 2018 – July 2022: Research Associate, Department of Materials Science and Engineering, The University of Sheffield, UK. Innovate UK funded project (104040) “FAST STEP 3 - Swarf Titanium to Engine Parts in 3 Steps” with Prof Martin Jackson.
Aug 2016 – Sept 2018: Research Associate, Department of Materials Science and Engineering, The University of Sheffield, UK. Innovate UK funded project (102577) "FAST-forge - from rutile sand to novel titanium alloy aerospace component in 3 steps" with Dr Martin Jackson.
Sept 2011 – Oct 2017: PhD in Metallurgy via the Advanced Metallic Systems Centre for Doctoral Training at The University of Sheffield, UK. Thesis: “A novel solid-state processing route to generate cost-effective titanium alloy components”
Sept 2007 – June 2011: MEng (Hons) Aerospace Engineering (1st Class) at The University of Sheffield, UK

Research interests: Current and future research focuses on utilising Field Assisted Sintering Technology’s (FAST) unique processing conditions, as well as understanding and overcoming its limitations, to solve real-world industrial manufacturing problems. Broad areas of interest include: (1) Improvements in FAST specimen geometric complexity and moving towards near net-shape. (2) Microstructural control and manipulation, including subsequent post-FAST processing. (3) Joining of dissimilar alloys and materials via FAST. (4) FAST modelling/simulation for improved process control and component optimisation.

Publications

Journal articles

Weston NS, Premoli D, Childerhouse T, Blanch OL & Jackson M (2024) Assessing the mechanical properties of out-of-specification additive manufacturing Ti-6Al-4V powder recycled through field-assisted sintering technology (FAST). Powder Metallurgy, 67(1), 70-85.
Marshall K, Schillinger P, Weston NS, Epler M & Jackson M (2022) A parametric study of the microstructural evolution of an advanced Ni-based superalloy powder when consolidated using Field Assisted Sintering Technology, compared to a hot isostatic pressing benchmark. Advances in Industrial and Manufacturing Engineering, 5, 100103-100103.
Childerhouse T, M’Saoubi R, Franca L, Weston N, Crawforth P & Jackson M (2022) The influence of machining induced surface integrity and residual stress on the fatigue performance of Ti-6Al-4V following polycrystalline diamond and coated cemented carbide milling. International Journal of Fatigue, 163, 107054-107054.
Weston NS & Jackson M (2020) FAST-forge of titanium alloy swarf: A solid-state closed-loop recycling approach for aerospace machining waste. Metals, 10(2). View this article in WRRO
Westona NS, Thomasa B & Jacksona M (2020) Exploitation of field assisted sintering technology (FAST) for titanium alloys. MATEC Web of Conferences, 321, 02006-02006.
Pope JJ, Calvert EL, Weston NS & Jackson M (2019) FAST-DB: A novel solid-state approach for diffusion bonding dissimilar titanium alloy powders for next generation critical components. Journal of Materials Processing Technology, 269, 200-207. View this article in WRRO
Weston NS, Thomas B & Jackson M (2019) Processing metal powders via field assisted sintering technology (FAST): a critical review. Materials Science and Technology, 35(11), 1306-1328.
Calvert E, Wynne B, Weston N, Tudball A & Jackson M (2018) Thermomechanical processing of a high strength metastable beta titanium alloy powder, consolidated using the low-cost FAST- forge process. Journal of Materials Processing Technology, 254, 158-170.
Benson LL, Benson Marshall LA, Weston NS, Mellor I & Jackson M (2017) On a Testing Methodology for the Mechanical Property Assessment of a New Low-Cost Titanium Alloy Derived from Synthetic Rutile. Metallurgical and Materials Transactions A, 48(11), 5228-5232. View this article in WRRO
Weston NS & Jackson M (2017) FAST-forge − a new cost-effective hybrid processing route for consolidating titanium powder into near net shape forged components. Journal of Materials Processing Technology, 243, 335-346. View this article in WRRO
Weston NS, Derguti F, Tudball A & Jackson M (2015) Spark plasma sintering of commercial and development titanium alloy powders. Journal of Materials Science, 50(14), 4860-4878. View this article in WRRO
Lister S, Levano Blanch O, Fernández Silva B, Weston N & Jackson M () A comparative study of microstructure and texture evolution in low cost titanium alloy swarf and powder recycled via FAST and HIP. Materials Science and Technology.

Conference proceedings papers

Weston NS, Holden C, Ingall D, Lunn D, Williams S, Balderson J & Jackson M (2021) FAST STEP 3: Field Assisted Sintering Technology for Swarf Titanium to Engine Parts in 3 steps. Euro PM2021 Congress Proceedings
Marshall LB, Benson LL, Weston NS, Repper SE, Jackson M & Mellor I (2017) Development of titanium alloy powders produced via the metalysis process. Proceedings Euro PM 2017: International Powder Metallurgy Congress and Exhibition
Weston N, Derguti F & Jackson M () Exploitation of Spark Plasma Sintering and One-Step Forging for Cost-Effective Processing of Titanium Alloy Powders (pp 123-128)

Media and public engagement

Finalist of the Parliamentary & Scientific Committee’s STEM for BRITAIN 2022 Poster Competition.
Henry Royce Institute Discover Materials Ambassador
Nick co-developed the ‘FAST-forge’ process, which has featured in a number of media publications:
- UK Government website news article “Porton Down scientists on brink of titanium revolution”, where the Secretary of State for Defence said: “This ground-breaking method is not only faster and cheaper but could see a huge expansion of titanium parts and equipment throughout the military. It is a clear example of how our world-class scientists are working behind the scenes to help our Armed Forces as well as bringing prosperity and security to Britain.”
- IMechE’s website news articles “Sheffield’s titanium revolution to meet tomorrow’s aerospace manufacturing needs” and “Production process promises cheaper titanium alloy components”.
- IOM3’s Materials World magazine article “The FAST-forge Process: Titanium Vs. Steel”.

ASM’s Advanced Materials and Processes magazine article “Titanium Production Forges Ahead”.