Professor Hongbiao Dong FREng

Professor Hongbiao Dong is Fellow of Royal Academy of Engineering. He is internationally renowned for digital manufacturing and solidification modelling and its application in metals, and has made unique contributions to the metals industry. He is the Director of EPSRC Centre for Doctoral Training in Digital Transformation of Metals Industry (DigitalMetal CDT), Deputy Head of School of Engineering.

Research in his team aims to explore the full potential of the application of AI in materials manufacturing, by fusing AI into materials science to develop robust, interpretable, and bias-free digital tools. These tools will be used to accelerate a net-zero carbon future and foster sustainability within the materials industry. The outcomes of research in his team bring knowledge-inspired decision making to the production routes of high value-added engineering structures, such as aero-engine components, deep-sea oil and gas transport systems. He successfully led a major European project on modelling of advanced welding (MintWeld), developing the first multi-scale modelling framework for arc welding. Its deployment in the subsea industry has mitigated pipeline failure risks, delivering significant cost savings. He chaired STFC-ISIS Engineering User Committee and a member of Steering Committee of the European Materials Modelling Council, a recipient of the Metrology for World Class Manufacturing award. 

His research has been exploited in various sectors, including in aerospace by Rolls-Royce, energy by the Welding Institute and steel by NISCO and Materials Processing Institute. He was a Research Chair of Royal Academy of Engineering sponsored with TWI, a Royal Society Industry Fellow hosted by Rolls-Royce Plc. He has played a key role in establishing international partnerships between UK and China, India and South Africa.

Currently available funded positions, to apply online DigitalMetal CDT

Highlights of Research Achievements:

AI in Materials Manufacturing & Data-Driven Modelling: Pioneered in application of AI and data-driven modelling of metallurgical processes, enabling on-line control of BOF steelmaking at NISCO, one of the world’s largest steel manufacturer. A seminal paper has received extensive citations.

Modelling of Alloy Solidification: Pioneered the simulation of columnar-to equiaxed transition in solidification revealing solute interaction in advancing dendrites. This research has significant industrial applications, including single-crystal growth of gas turbines, welding and additive manufacturing. A seminal paper (doi.org/10.1016/j.actamat.2004.10.019, 2005) has garnered significant citations.

Arc Welding Modelling Framework: Led the development of the first multi-scale multi-physics framework for arc welding modelling through the EU-FP7 project. The framework's application in subsea pipelines reduced the risk of failures, delivering significant cost savings. Final Report Summary – MINTWELD is available here

Casting Defect Reduction: Developed a novel and practical solution, involving surface passivation, to reduce casting defects in single-crystal components, applied to casting of gas turbine blades, enabled production rates to meet demanding engine delivery schedules. Contributions include two international patents: EU EP2166133B1 and USA US8192564B2, and over 50 joint publications with Rolls-Royce Plc.

Advancing Arc Welding and Additive Manufacturing: Designed a practical solution to optimise arc welding and arc-wire additive manufacturing by controlling internal melt flow via surface-active elements. The breakthrough paper has been extensively cited, was featured in multiple news stories, and highlighted in Nature Communications’ cutting-edge materials science and metallurgy collections. It also appeared in the Diamond Annual Review 2020.

Academic Leadership:
FREng, Fellow of Royal Academy of Engineering
FIMMM, Fellow of IOM3 - The Institute of Materials, Minerals & Mining
Research Chair of Royal Academy of Engineering, sponsored by TWI Ltd (2016-2023
Senior Fellow of the Chinese Society for Metals
Royal Society Industry Fellow, sponsored at Rolls-Royce Plc (2006-2008)
Vice Editor-in-Chief, International Journal of Minerals, Metallurgy and Materials (2020-)
Associate Editor, Materials Genome Engineering Advances, (2023-)
Review Panel member, German Research Foundation (DFG)
Review Panel member of China Natural Science Foundation Review panel
Review Panel member of UK EPSRC Peer Review College
Chair of Engineering User Group of ISIS facility of UK Scientific Facility Council (STFC) (2013-2018)
Board member of Review Committee, Materials and Metallurgical Transaction: A (2012-)
Board member of European Materials Modelling Council, Working Group 2 – Modelling & Multiscale (09/2009 - )
Recipient of the Metrology for World Class Manufacturing award (2000)

Major Research Grants and Contracts:

EPSRC Centre for Doctoral Training in Digital Transformation of Metals Industry (DigitalMetal CDT)
NISCO UK Research Centre
EPSRC Centre for Doctoral Training in Innovative Metal Processing (IMPaCT CDT)
European Commission: Modelling of Interface Evolution in Advanced Welding (MintWeld)
Horizon 2020: Digital "plug and produce" online welding equipment and consumables platform for manufacturing
EPSRC Design of Novel Brazing Filler Metals using High Entropy Alloy Concepts, led by the University of Sheffield in collaboration with TWI
Innovate UK: High Entropy Alloys for Targeted Additive Manufacturing Aerospace Applications
Horizon 2020: Develop novel coatings for CCUS (FORGE).

Available Positions:

Are you ready to lead the future of manufacturing and digital innovation? Join the DigitalMetal CDT, a ground-breaking initiative to revolutionise the metals industry, collaborating with world-renowned universities—Leicester, Birmingham, Nottingham, Loughborough, and Warwick—and industry leaders like Rolls-Royce. gaining unparalleled access to state-of-the-art resources, cutting-edge research opportunities, and a vibrant network of innovators.

This is your chance to drive the next wave of advancements in manufacturing and make a lasting impact on a global scale—be part of the transformation!

To apply on-online: DigitalMetal CDT

My list of publications can be found via Google Scholar

‪Hongbiao Dong‬ - ‪Google Scholar‬

I have cultivated a broad teaching portfolio, and delivered courses spanning engineering design, materials science, structures, materials thermodynamics and kinetics, design management, aerospace materials and engineering leadership.

Key educational initiatives include:

CDIO Framework Implementation: At Leicester I have led our adoption of the CDIO (Conceive, Design, Implement, Operate) educational framework, which integrates real-world problem-solving into engineering design teaching. This has transformed our curriculum, making engineering design the most popular subject in the school since 2009. I will be happy to lead such an initiative for Engineering at Birmingham.

Student Engagement: Through the CDIO initiative, students tackle business-relevant challenges, preparing them to innovate in industry settings. This approach has consistently enhanced student satisfaction and employability outcomes.

Taught modules at Leicester include

EG1002: Engineering Design I (module coordinator)
EG2002: Engineering Design II (module coordinator)
EG2101: Materials (I): Properties of Engineering Materials
EG2111: Materials & Structures
EG2150: Materials (II): Processing of Engineering Materials
EG3101: Materials (III): Failure Mechanisms of Engineering Materials
EG4021: Engineering Design and Management (I) (module coordinator)
EG4022: Engineering Design and Management (II) (module coordinator)
EG4421: Holistic Gas Turbine Design: (in collaboration with Rolls-Royce)
EG4360: Aerospace Materials 
EG7038: Aerospace Materials
EG7101: Materials Thermodynamics and Phase Diagrams 
EG7102: Kinetics and Microstructure Modelling