Project Assistant: Optimisation of metal passivation process (Summer Scheme)
Warwick Manufacturing Group are working alongside a local business to offer a Summer Scheme role.The role will involve the optimisation of the metal electrode passivation process, analysis of the amalgamated surfaces using electron microscopy and testing its performance inside of a fully assembled product.
This role is for an 8 week fixed term contract over the Summer 2018 period. This is part of the WMG centre High Value Manufacturing Catapult which provides a valuable opportunity to gain industry experience, which may also lead to future job opportunities.
Duties and responsibilities
The project will include:
• Carrying out a literature search on metal amalgamation processes; particularly zinc amalgam (Zn-Hg). Establishing optimum concentration of mercury solution to achieve the desired level of metal passivation.
• Review the back ground and understand the product development up-to-date. Analyse/understand the electrochemical reaction/processes occurring inside the working grease discharge unit. Study the chemistry behind the electrochemical reaction occurring between the metal components and electrolyte, and hydrogen evolution reaction to improve the overall performance of the product.
• Review current chemical process and the reactions involved in creating the amalgam on the surface of the zinc metal. Based on development work undertaken to date work to identify an optimum passivation process that gives the required amalgam in a cost effective manufacturing process, and develop this into a robust, achievable and documented process, fully risk assessed and suitable controls established for the process to become the adopted manufacturing process within the company.
• Having established a proposed optimum process to produce the metal amalgam, produce parts and analyse the surface using optical microscopy and energy-dispersive X-ray spectroscopy.
• Assemble the units and monitor the grease discharge at different temperatures and settings; produce good quality graphs for use on the company website/brochures.
• Establish best practice manufacturing processes for:-
1 The metal amalgamation.
2 The electrolyte preparation and subsequent handling of the mixture (acidic solution).
3 Control of activities within the company’s laboratory facility.
4 Documenting processes and complete risk assessment evaluations for all activities undertaken in the laboratory and manufacturing facility involving the use of chemicals.
5 Establish the quality system checks and controls necessary to meet the high standard required for component production.
6 Produce a report on findings and process optimisation, and conduct a handover to the manufacturing personnel.
Skills and experience
This post is not eligible for visa sponsorship, so applicants must have existing eligibility to work in the UK for the duration of the contract.
• Educated to, or working towards a relevant science or engineering degree (or equivalent)
• Analytical thinker with a practical approach to problem solving
• Ability to be flexible to work in different environments
• Ability to learn new skills, work flexibly and collaboratively as part of a team and on own initiative
• Organised and motivated with a focus on results
• Good knowledge of chemistry
• Have practical laboratory skills and be able to communicate effectively both in reports and verbally
• Ability to analyse and interpret results
• Be able to carry out general calculations and have a good scientific understanding and approach to investigations.
• Experience of using stereoscope and scanning electron microscope (SEM) be beneficial but not mandatory as training will be provided
Interviews will take place May 2018
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