Professor Jeffery William Brooks BSc, PhD, CEng, FIMMM

Professor Jeffery William Brooks

School of Metallurgy and Materials
Hanson Professor of Industrial Metallurgy
Director of the Partnership for Research in Simulation of Manufacturing and Materials (PRISM2)
Director of the Advanced Materials Characterisation and Simulation Hub (AMCASH)

Contact details

Telephone
+44 (0) 121 414 7836
Fax
+44 (0) 121 414 7373
Email
j.brooks@bham.ac.uk
Address
School of Metallurgy and Materials
University of Birmingham
Edgbaston
Birmingham
B15 2TT
UK

Professor Brooks is a recognised authority on the microstructure, mechanical properties and the manufacturing process routes of the materials used in aerospace components. He has developed finite element modelling techniques for stress analysis and manufacturing process simulation that are applied in industry and academia. He has an established track record in initiating, growing and managing research groups in both industry and research and technology organisations.

In his current role as Director of the Partnership for Research in Simulation of Manufacturing and Materials (PRISM2) at the University of Birmingham he is responsible for the strategic direction of the centre and delivery of the research portfolio which is executed by a team of 20 post-doctoral researchers and PhD students. The PRISM2 partnership conducts both academic and industrially focussed research on developing multiscale physically based models of material behaviour for the prediction of the microstructure and properties of engineering components. The approach covers simulation over a wide range of length scales, from atomistic calculations through dislocation dynamics and crystal plasticity, to provide a predictive capability at the macroscopic scale. Industrial collaborations include research for Rolls-Royce, TIMET, Doncasters and Special Metals on the processing and manufacture of nickel and titanium alloys and components.

Professor Brooks is also a director of the European Regional Development Fund (ERDF) funded Advanced Materials Characterisation and Simulation Hub (AMCASH). This project aims to promote business investment in R&D and innovation by significantly enhancing knowledge transfer between the University and local SMEs through in-depth technical assistance and collaborative research. The project builds on the successful Centre for Advanced Simulation & Modelling for Manufacturing (CASiM2), also sponsored by the ERDF, which disseminated modern modelling methods to industry and concentrated on interaction with small to medium enterprises (SME) operating in the supply chain. This ERDF funding underpins the development of a suite of integrated computational materials engineering (ICME) modelling tools which includes the prediction of the complex liquid flow and thermal fields occurring in welding and additive manufacturing. These are then linked to mesoscale simulations of the solidification grain structures and subsequent crystal plasticity models of the macroscopic response.

Previous accomplishments include:

  • Established the Advanced Forming Research Centre (AFRC) as a significant research entity with 70 staff and attracted £30M from the HVM Catapult.
  • Drafted the lifing and risk assessment content for the MoD Propulsion Integrity Policy.
  • Developed a microstructural model for the process optimisation of titanium alloy semi-finished product used by industry in both the UK and the US.
  • Initiated and led a materials modelling group and achieved £4M turnover in five years.
  • Developed isothermal forging technology which led to the installation of a UK capability for the manufacture of gas turbine discs for the EJ200 Typhoon engine.
  • Developed a bolster design for precision forging which is now the UK industry standard.

Qualifications

Hanson Professor of Industrial Metallurgy

  • FIMMM Fellow of the Institute of Materials, Minerals and Mining (IOMMM) 2000
  • CEng Chartered Engineer, Engineering Council 1986
  • MIM Member of the Institute of Metals (IOM) 1986
  • PhD in Metallurgy and Materials, University of Birmingham 1978
  • BSc in Metallurgy and Materials, University of Birmingham 1975

Biography

Professor Brooks obtained his PhD from Birmingham University in 1978 and subsequently held a number of positions in industry including:

  • Technical Manager – QinetiQ Limited
  • Technical Leader – MoD DERA Farnborough
  • Chief Metallurgist – Doncasters plc
  • Senior Metallurgist – INCO Alloy Products Limited

His early career in manufacturing concentrated on developing modelling techniques for the simulation of the complex interaction between plastic deformation and thermal history that occurs in both industrial metal working processes and in service components. This allowed the prediction of microstructural development, the mechanical properties and performance of the manufactured products.

His research has concentrated on maintaining the structural integrity of aerospace components which requires reproducible production methods to provide consistent properties and low levels of defects. This is especially true for rotating parts in aero gas turbine engines and particularly so for the turbine discs where an uncontained failure could result in the loss of the aircraft. In his role with the MoD Prof. Brooks initiated and led research for the provision of support services and advice on the manufacture and structural integrity of the propulsion systems in all the major RAF and RN platforms (including Typhoon, Tornado, Harrier, Merlin, Chinook). Later work on manufacturing aerospace materials and component lifing led to many collaborative projects with industries including Rolls-Royce plc, The Boeing Company and their tier one suppliers.

Professor Brooks returned to academia in 2009 as Professor of Manufacturing with an EPSRC Star Professor Award at the University of Strathclyde as Research Director for the Advanced Forming Research Centre (AFRC). In this role he was responsible for the strategic development of the centre and coordination of the AFRC research strategy including the core membership research programme and its academic conduct. He chaired the AFRC Technical Board and managed the relationships with partner Universities, the Scottish Research Partnership in Engineering and the core industrial members, Aubert and Duval, Boeing, Mettis Aerospace, Rolls-Royce and TIMET. He was responsible for the growth of the Centre through attracting funding from new industrial members, research council grants, government sources (Business Innovation and Skills (BIS), Technology Strategy Board (TSB) and Scottish Enterprise) and the European Union. This resulted in rapid growth of the AFRC to 70 staff with a turnover of £7M per annum and over 20 member companies and a membership research portfolio of over £2.5M in three years.

He bid successfully for the £4M EPSRC Industrial Doctorate Centre in Advanced Forming and Manufacture to provide a training platform for new researchers in the AFRC. He was also responsible for the business plan which ensured AFRC participation in the UK government sponsored High Value Manufacturing Catapult which attracted a further £30M investment in the AFRC. This facilitated expansion of the building and the acquisition of industrial capabilities for superplastic forming, flow forming and rotary forging.

He took up the position of Hanson Professor of Industrial Metallurgy at Birmingham University in 2013 to further his research interests in the application of multiscale modelling approaches to the manufacture and performance of advanced alloys.

He is actively involved with advisory boards and conference organisation including membership of the advisory committee for the NUMMAN project at Manchester University and the organising committee for the 12th International Conference on Technology of Plasticity. He also is an invited panel member for the NASA Vision 2040 Study – A Vision for Multiscale Materials and Structural Modelling. He has published many peer reviewed papers and regularly gives invited keynote presentations at international conferences and meetings.

Teaching

Director of the EPS MSc in Integrated Computational Materials Engineering

Postgraduate supervision

  • Matteo Villa PhD - Numerical simulation of fusion welding processes on Ti-6Al-4V
  • Stefano Cademartori EngD - Mathematical and numerical modelling of core injection for investment casting applications
  • Federica Di Simone PhD – Investigation of high integrity joining processes for nickel based alloys
  • Mushfiqur Rahman PhD – Physics based modelling of microstructure evolution in novel nickel based alloys
  • Gavin Yearwood PhD – Development of a location specific mechanical property prediction tool for RR1000 nickel superalloy
  • Ekoh Ehigiator- Blown powder repair capability development and modelling

Research

Application of multiscale modelling techniques to manufacturing and performance.

  • Fusion welding
  • Inertia welding
  • Additive manufacture
  • Hot isostatic pressing

Development of process modelling techniques for forming and forging processes

  • Forging and extrusion modelling
  • Flow forming simulation
  • Superplastic forming
  • Sheet forming

Component Performance modelling

  • Creep and fatigue modelling
  • Thermal barrier coating performance modelling
  • Location specific property prediction

Materials development

  • High temperature nickel alloy development
  • Titanium aluminide manufacture
  • Metal matrix composite performance and manufacture
  • Ceramic matrix composite performance and manufacture

Microstructural characterisation and analysis

  • In-situ microscopy of crystal defects
  • Transmission electron microscopy
  • X-ray dispersive micro-analytical techniques

Publications

Recent journal papers

On the processing of steel rod for agricultural conveyor systems: Materials characterisation and modelling, R.P Turner, B. Permual, B. Thota, J.W. Brooks, Journal of Manufacturing Processes; 26 (Apr), pp22-30 (2017).

Keyhole formation and thermal fluid flow-induced porosity during laser fusion welding in titanium alloys: Experimental and modelling, C Panwisawas, B Perumal, RM Ward, N Turner, RP Turner, JW Brooks, H.C. Basoalto, Acta Materialia; 126, 251-263 (2017).

Mesoscale modelling of selective laser melting: Thermal fluid dynamics and microstructural evolution, C. Panwisawas, C. Qiu, M.J. Anderson, Y. Sovani, R.P. Turner, M.M Attallah, J.W. Brooks, H.C. Basoalto, Computational Materials Science; 126, 479-490 (2017).

An Improved Method of Capturing the Surface Boundary of a Ti-6Al-4V Fusion Weld Bead for Finite Element Modeling, R.P. Turner, M. Villa, C. Panwisawas, Y. Sovani, B. Perumal, R.M. Ward, J.W . Brooks, Metallurgical and Materials Transactions B; 47 (1), 485-94 (2016)

Calculating the energy required to undergo the conditioning phase of a titanium alloy inertia friction weld, R.P. Turner, D. Howe, B. Thota, R.M. Ward, H.C. Basoalto, J.W. Brooks; Journal of Manufacturing Processes, 24 (1), 186-194 (2016).

An Integrated Modeling Approach for Predicting Process Maps of Residual Stress and Distortion in a Laser Weld: A Combined CFD–FE Methodology, R.P. Turner, C Panwisawas, Y Sovani, B Perumal, RM Ward, JW Brooks, H.C. Basoalto; Metallurgical and Materials Transactions B; 47 (5), 2954-2962 (2016).

On the Role of Thermal Fluid Dynamics into the Evolution of Porosity During Selective Laser Melting, C. Panwisawas, C. Qiu, Y. Sovani, J.W. Brooks, M.M. Attallah, H.C. Basoalto, Scripta Materialia, 105, Pages 14-17 (2015)

On the Role of Melt Flow into the Surface Structure and Porosity Development During Selective Laser Melting,  C. Qiu, C. Panwisawas, R.M. Ward, H.C. Basoalto, J.W. Brooks, M.M Attallah,  Acta Materialia, 96, 72-79, (2015)

Recent conference papers

Materials Physics of Additive Manufacturing: An ICME approach, C. Panwisawas, M.J. Anderson, Y. Sovani, T.F. Flint, R.P. Turner, J.W. Brooks, H.C. Basoalto, Gordon Research Seminar and Gordon Research Conference on Physical Metallurgy, University of New England, Biddeford –USA (Jul 2017).

The simulation of precipitate kinetics in Inconel718 additive manufactured components, M. Anderson, C. Panwisawas, Y. Sovani, R.P. Turner, H.C. Basoalto, J.W. Brooks, TMS 4th World Congress on ICME, Ann Arbor, USA (May 2017).

A Process-Map based ICME Approach to Fusion Welding of Titanium Alloys,Y. Sovani, C. Panwisawas, R.P. Turner, B. Saunders, N. Palumbo, H. Basoalto, J.W. Brooks; TMS 4th World Congress on ICME, Ann Arbor, USA (May 2017).

A Continuum Approach to the Heterogeneous Evolution of Dislocation Density Within a Two-Phase Microstructure, J. Little, H. Basoalto, J.W. Brooks, International Conference on Plasticity, Damage, and Fracture 2017, Puerto Vallarta - Mexico (January 2017).

Coupling a CFD and FE Analysis for Welding Simulations, R.P. Turner, Y. Sovani, C. Panwisawas, B. Perumal, R.M. Ward, H.C. Basoalto, J.W. Brooks, 10th International Trends in Welding Research Conference, Tokyo (Oct 2016).

Importance of flow-stress on microstructure evolution in the modelling of Inertia friction welding, F. Di Simone, S. Bray, H.C. Basoalto, J.W. Brooks, 10th International Trends in Welding Research Conference, Tokyo (Oct 2016).

Predictions of the influence of microstructure variations on property scatter in Additive Manufacturing, C. Panwisawas, Y. Sovani, M.J. Anderson, R.P. Turner, J.W. Brooks and H.C. Basoalto, 8th International Conference on Multi-scale Materials Modelling (MMM), Dijon – France, (Oct 2016).

A Multi-scale, multi-physics approach to modelling of additive manufacturing in Nickel-based superalloys, C. Panwisawas, Y. Sovani, M.J. Anderson, R.P. Turner, N. Palumbo, B. Saunders, I. Choquet, J.W. Brooks, H.C. Basoalto, Superalloys 2016, Pennsylvania – USA (Sept 2016).

Bibliography from 2008-14 (representative papers in bold)

 Modelling the High Temperature Behaviour of Titanium Alloys, H.C.Basoalto and J.W.Brooks, 2014, AIAA  SciTech 2014, Washington

Prediction not extrapolation, J.W.Brooks and H.C.Basoalto, 2014, Workshop: Accelerated Testing of Materials, IOM3, Derby

Incremental Forming Techniques – Blacksmithing for the 21st Century, J.W.Brooks and H.C.Basoalto, 2014, Advances in Metals Manufacturing Technologies, SMEA CONFERENCE AND EXHIBITION, Sheffield

On the metallurgical modelling of Ti-6Al-4V in Welding processes, M. Villa, R.Turner, H.Wang, F.Boitout, J. W. Brooks and M.Ward, 2014

Modelling the Rotary Friction Welding Process for Titanium Alloys, R.Turner, B.Thota, D.Howe, H.C.Basoalto and J.W.Brooks, 2014, OPTIMoM 2014

Multiscale Materials Modelling of Fusion Welding, C.Panwisawas, Y.Sovani, R.Turner, J.W.Brooks and H.C. Basoalto, 2014, OPTIMoM 2014

The β recrystallisation characteristics of the α/β titanium alloy Ti-6Al-4V, M.Allen, P.Blackwell, M.Thomas and J.W.Brooks, 2014, OPTIMoM 2014

Forming the Future, J.W.Brooks, 2013, Formed in the UK, IOM3, Warwick

Comparison of fatigue crack propagation behaviour in two gas turbine disc alloys under creep fatigue conditions: evaluating microstructure, environment and temperature effects,  S. Everitt, R. Jiang, N. Gao, M. J. Starink, J. W. Brooks and P. A. S. Reed, 2013, Materials Science and Technology, 29, 7 p781

Friction during precision forging of high temperature aerospace materials, J.W. Brooks, 2012, Materials Science and Technology, Vol 28, No 5, p528

Mophological and textural evolution of the alpha phase during hot deformation of two-phase Ti-6Al-4V, B.Perumal, M.Rist, S.Gungor and J.W.Brooks, 2011, Titanium 2011, 12th World Conference on Titanium

Modelling the High Temperature Deformation of Titanium Alloys, H.C.Basoalto and J.W.Brooks, 2011, Titanium 2011, 12th World Conference on Titanium

Lifing Approaches and Component Classification – Overview of Methods, J.W.Brooks and P.H.Tranter, Encyclopedia of Aerospace Engineering, 2010, John Wiley & Sons

Evaluation of Mechanical Properties for the Simulation of Super Plastic Forming, J.W.Brooks, 2010, EuroSPF 2010, San Sebastian, Spain

The Application of Microstructure and Property Modelling to the Prediction of Forged Component Performance, J.W.Brooks and H.C.Basoalto, 2010, OPTIMOM, Cambridge

Advanced High Temperature Materials: Gas Turbine Fatigue, J.W.Brooks, 2010, Australian Gas Turbine Conference, Melbourne

Friction and wear during precision forging of high temperature aerospace materials, J.W.Brooks, 2010, IOMMM High Temperature Wear and Erosion, November 2010, Derby

Mechanical performance of extruded Ti–46Al–5Nb–1W titanium aluminide, A. Wisbey*, H. Singh, K. Lucas and J.W.Brooks, 2010, Materials Science and Technology, Vol 27, No 6, p1059

Probabilistic Property Prediction of Aero-engine Components for Fatigue, J.W. Brooks, H.C. Basoalto, R. Sahota and P. Tranter, Proceedings of ASME Turbo Expo 2010, GT2010, 2010, Glasgow, UK, GT2010-22708

H.C.Basoalto, J.W.Brooks and S.Everitt, Life prediction of thermal barrier coatings, Gas Turbines: High Temperature Coatings and Life Extension Conference, 2009.

H.C.Basoalto, J.W.Brooks, K. A.Long and J.R.Nicholls, Deposition technologies for thermal barrier coatings, Gas Turbines: High Temperature Coatings and Life Extension Conference, 2009.

Multiscale microstructure modelling for nickel based superalloys, H. C. Basoalto, J. W. Brooks and I. Di Martino, 2009, Materials Science and Technology, Vol 25, No 2, p221

A Micromechanics Approach to Residual Life Assessment of Nickel-Based Superalloys, H.C. Basoalto , A. Wisbey and J.W. Brooks, 2009, ICFT12

The Evaluation of Repair Techniques for IN 738 and MarM002 Nickel Superalloys, J.W.Brooks, H.C.Basoalto, A.Wisbey, G.Kidd, S. McArthur and C.M. Fordyce, 2009, RTO-MP-AVT-163

H.C.Basoalto, B.Vermeulen, J.W.Brooks, G.Coventry, S.Williams, J.Mason-Flucke and S.Bagnall, A New Hyperbolic Tangent Modelling Approach for Creep of the Single  Crystal Nickel-Based Superalloy CMSX4, in Superalloys 2008, Ed. R. Reed et al. 2008.