Professor David Penney

Professor

Materials Science and Engineering

+44 (0) 1792 606706

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Academic Office - A216
Second Floor
Engineering East
Bay Campus

Research Links

https://orcid.org/0000-0002-8942-8067

About

David is an industry focused materials and manufacturing engineer with experience of working in both academia and industry. Over the years, David has worked to create simple, flexible route for industry and academia to work together for either training or research purposes. Over £30 million of grant income has been won to support this activity and he continues to develop this area. In 2016, David won the Frank Fitzgerald award from the IOM3 for his personal contribution to the Iron and Steel industry.

David is a co-director and Principle investigator of the £15million Materials and Manufacturing Academy (M2A). The M2A incorporates the EPSRC funded COATED2 Centre for Doctoral Training and works closely with industry to industry focused research and training. Over the next 4 years, over 140 people will graduate from the M2A, each having undertaken a large research project in collaboration with an industry partner.
David co-created the Work Based Learning programme, Materials Education Training and Learning (METaL) which aims to up skill the existing workforce through a series of flexible short courses in the field of materials and manufacturing.

Areas Of Expertise

Metallurgy
Galvanising
Metallic coatings
Corrosion
Stainless steel
Zinc aluminium alloys
External funding
Industrial engagement
Doctoral training

Publications

Research Highlights

Berry, L., Phillips, C., & Penney, D. (2016). Understanding the role of snout contamination in the formation of an oxide based defect in hot dip galvanised coating. Surface and Coatings Technology, 306, 397-407.
https://doi.org/10.1016/j.surfcoat.2016.02.009, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa26470
http://ac.els-cdn.com/S0257897216300718/1-s2.0-S0257897216300718-main.pdf?_tid=a404fc26-33af-11e6-83ca-00000aab0f26&acdnat=1466074194_4e62c4a142dc6744784d6b5a7661c27a
Sullivan, J., Penney, D., Elvins, J., & Khan, K. (2016). The effect of ultrasonic irradiation on the microstructure and corrosion rate of a Zn–4.8wt.% Al galvanising alloy used in high performance construction coatings. Surface and Coatings Technology, 306, 480-489.
https://doi.org/10.1016/j.surfcoat.2016.01.050, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa26013
Mehraban, S., Malone, J., Lavery, N., Sullivan, J., Penney, D., & Brown, S. (2017). Increased Corrosion Resistance of Zinc Magnesium Aluminum Galvanised Coating through Germanium Additions. In ECS Transactions (pp. 1-15).
https://doi.org/10.1149/07530.0001ecst, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa32175
Holmes, M., Penney, D., Lavery, N., Brown, S., Brown, S., Lavery, N., & Penney, D. (2017). A numerical investigation assessing the symmetry of burden charging in a blast furnace using different chute designs. Ironmaking & Steelmaking, 1-9.
https://doi.org/10.1080/03019233.2017.1303893, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa32295
Wint, N., Sullivan, J., & Penney, D. (2017). The Role of pH on the Inhibition of Aqueous Zinc Corrosion by L-tryptophan. Journal of The Electrochemical Society, 164(7), C356-C366.
https://doi.org/10.1149/2.0981707jes, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa33650
Wint, N., Leung, J., Sullivan, J., Penney, D., & Gao, Y. (2018). The galvanic corrosion of welded ultra-high strength steels used for automotive applications. Corrosion Science, 136, 366-373.
https://doi.org/10.1016/j.corsci.2018.03.025, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa39106
http://dx.doi.org/10.1016/j.corsci.2018.03.025
Charles, R., Douglas, P., Baker, J., Carnie, M., Douglas, J., Penney, D., & Watson, T. (2018). Platinized counter-electrodes for dye-sensitised solar cells from waste thermocouples: A case study for resource efficiency, industrial symbiosis and circular economy. Journal of Cleaner Production, 202, 1167-1178.
https://doi.org/10.1016/j.jclepro.2018.08.125, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa43529
Taylor, T., Penney, D., & Yanagimoto, J. (2020). One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts. Steel Research International, 91(10), 2000085
https://doi.org/10.1002/srin.202000085, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa54858
Taylor, T., Kim, K., Zhang, J., Penney, D., & Yanagimoto, J. (2021). TRIP assisted press hardened steel by the anisothermal bainitic ferrite transformation. Journal of Materials Processing Technology, 289, 116950
https://doi.org/10.1016/j.jmatprotec.2020.116950, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa55601
Wint, N., Malla, A., Cooze, N., Savill, T., Mehraban, S., Dunlop, T., Sullivan, J., Penney, D., Williams, G., & McMurray, H. (2021). The ability of Mg2Ge crystals to behave as ‘smart release’ inhibitors of the aqueous corrosion of Zn-Al-Mg alloys. Corrosion Science, 179, 109091
https://doi.org/10.1016/j.corsci.2020.109091, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa55603
Ayres, J., Penney, D., Evans, P., & Underhill, R. (2022). Effect of intercritical annealing on the mechanical properties of dual-phase steel. Ironmaking and Steelmaking, 49(8), 1-7.
https://doi.org/10.1080/03019233.2022.2062163, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa60158
Malla, A., Sullivan, J., Penney, D., Dunlop, T., & Barker, P. (2023). Mechanistic study on the corrosion behaviour of Zinc and Zinc-Calcium alloys designed for enhanced metallic coatings in the presence of chloride and phosphate ions. Corrosion Science, 213, 110956
https://doi.org/10.1016/j.corsci.2022.110956, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa62266
ALPARONE, G., Penney, D., Jewell, E., Sullivan, J., & Mills, C. (2023). The Effect of Sliding Speed on the Tribological Properties of Ceramic Materials. Materials, 16(23), 7252
https://doi.org/10.3390/ma16237252, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa65094
Alparone, G., Penney, D., Sullivan, J., Edy, J., & Mills, C. (2024). Al2O3 Coatings for Protection of Stainless Steel 316L against Corrosion in Zn-Al and Zn-Al-Mg. Coatings, 14(5), 606
https://doi.org/10.3390/coatings14050606, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa66461
http://dx.doi.org/10.3390/coatings14050606
Britton, D., Penney, D., Malla, A., Mehraban, S., Sullivan, J., Goldsworthy, M., McGettrick, J., Johnston, R., Mitchell, R., & Challinor, C. (2024). Effect of antimony additions on the microstructure and performance of Zn–Mg–Al alloy coatings. npj Materials Degradation, 8(1)
https://doi.org/10.1038/s41529-024-00481-7, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa66612
http://dx.doi.org/10.1038/s41529-024-00481-7
Malla, A., Sullivan, J., Penney, D., Sackett, E., Lancaster, R., & Barker, P. (2024). The Effect of Germanium Additions on the Mechanical Properties of Zn-Mg-Al Alloys. Metals, 14(7), 820
https://doi.org/10.3390/met14070820, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa67176
Malla, A., Sullivan, J., Penney, D., Goldsworthy, M., Britton, D., Williams, G., Goodwin, F., & Cardoso, A. (2024). Mechanistic investigation on the influence of coating weights on the corrosion behaviour of hot-dip-galvanised Zn-Mg-Al coatings. npj Materials Degradation, 8(1)
https://doi.org/10.1038/s41529-024-00494-2, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa67467

All Research

Journal Articles

Malla, A., Sullivan, J., Penney, D., Goldsworthy, M., Britton, D., Williams, G., Goodwin, F., & Cardoso, A. (2024). Mechanistic investigation on the influence of coating weights on the corrosion behaviour of hot-dip-galvanised Zn-Mg-Al coatings. npj Materials Degradation, 8(1)
https://doi.org/10.1038/s41529-024-00494-2, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa67467
Malla, A., Sullivan, J., Penney, D., Sackett, E., Lancaster, R., & Barker, P. (2024). The Effect of Germanium Additions on the Mechanical Properties of Zn-Mg-Al Alloys. Metals, 14(7), 820
https://doi.org/10.3390/met14070820, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa67176
Britton, D., Penney, D., Malla, A., Mehraban, S., Sullivan, J., Goldsworthy, M., McGettrick, J., Johnston, R., Mitchell, R., & Challinor, C. (2024). Effect of antimony additions on the microstructure and performance of Zn–Mg–Al alloy coatings. npj Materials Degradation, 8(1)
https://doi.org/10.1038/s41529-024-00481-7, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa66612
http://dx.doi.org/10.1038/s41529-024-00481-7
Alparone, G., Penney, D., Sullivan, J., Edy, J., & Mills, C. (2024). Al2O3 Coatings for Protection of Stainless Steel 316L against Corrosion in Zn-Al and Zn-Al-Mg. Coatings, 14(5), 606
https://doi.org/10.3390/coatings14050606, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa66461
http://dx.doi.org/10.3390/coatings14050606
ALPARONE, G., Penney, D., Jewell, E., Sullivan, J., & Mills, C. (2023). The Effect of Sliding Speed on the Tribological Properties of Ceramic Materials. Materials, 16(23), 7252
https://doi.org/10.3390/ma16237252, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa65094
Malla, A., Sullivan, J., Penney, D., Dunlop, T., & Barker, P. (2023). Mechanistic study on the corrosion behaviour of Zinc and Zinc-Calcium alloys designed for enhanced metallic coatings in the presence of chloride and phosphate ions. Corrosion Science, 213, 110956
https://doi.org/10.1016/j.corsci.2022.110956, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa62266
Ayres, J., Penney, D., Evans, P., & Underhill, R. (2022). Effect of intercritical annealing on the mechanical properties of dual-phase steel. Ironmaking and Steelmaking, 49(8), 1-7.
https://doi.org/10.1080/03019233.2022.2062163, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa60158
Taylor, T., Kim, K., Zhang, J., Penney, D., & Yanagimoto, J. (2021). TRIP assisted press hardened steel by the anisothermal bainitic ferrite transformation. Journal of Materials Processing Technology, 289, 116950
https://doi.org/10.1016/j.jmatprotec.2020.116950, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa55601
Wint, N., Malla, A., Cooze, N., Savill, T., Mehraban, S., Dunlop, T., Sullivan, J., Penney, D., Williams, G., & McMurray, H. (2021). The ability of Mg2Ge crystals to behave as ‘smart release’ inhibitors of the aqueous corrosion of Zn-Al-Mg alloys. Corrosion Science, 179, 109091
https://doi.org/10.1016/j.corsci.2020.109091, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa55603
Taylor, T., Penney, D., & Yanagimoto, J. (2020). One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts. Steel Research International, 91(10), 2000085
https://doi.org/10.1002/srin.202000085, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa54858
Charles, R., Douglas, P., Baker, J., Carnie, M., Douglas, J., Penney, D., & Watson, T. (2018). Platinized counter-electrodes for dye-sensitised solar cells from waste thermocouples: A case study for resource efficiency, industrial symbiosis and circular economy. Journal of Cleaner Production, 202, 1167-1178.
https://doi.org/10.1016/j.jclepro.2018.08.125, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa43529
Wint, N., Leung, J., Sullivan, J., Penney, D., & Gao, Y. (2018). The galvanic corrosion of welded ultra-high strength steels used for automotive applications. Corrosion Science, 136, 366-373.
https://doi.org/10.1016/j.corsci.2018.03.025, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa39106
http://dx.doi.org/10.1016/j.corsci.2018.03.025
Holmes, M., Penney, D., Lavery, N., Brown, S., Brown, S., Lavery, N., & Penney, D. (2017). A numerical investigation assessing the symmetry of burden charging in a blast furnace using different chute designs. Ironmaking & Steelmaking, 1-9.
https://doi.org/10.1080/03019233.2017.1303893, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa32295
Wint, N., Sullivan, J., & Penney, D. (2017). The Role of pH on the Inhibition of Aqueous Zinc Corrosion by L-tryptophan. Journal of The Electrochemical Society, 164(7), C356-C366.
https://doi.org/10.1149/2.0981707jes, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa33650
Berry, L., Phillips, C., & Penney, D. (2016). Understanding the role of snout contamination in the formation of an oxide based defect in hot dip galvanised coating. Surface and Coatings Technology, 306, 397-407.
https://doi.org/10.1016/j.surfcoat.2016.02.009, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa26470
http://ac.els-cdn.com/S0257897216300718/1-s2.0-S0257897216300718-main.pdf?_tid=a404fc26-33af-11e6-83ca-00000aab0f26&acdnat=1466074194_4e62c4a142dc6744784d6b5a7661c27a
Sullivan, J., Penney, D., Elvins, J., & Khan, K. (2016). The effect of ultrasonic irradiation on the microstructure and corrosion rate of a Zn–4.8wt.% Al galvanising alloy used in high performance construction coatings. Surface and Coatings Technology, 306, 480-489.
https://doi.org/10.1016/j.surfcoat.2016.01.050, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa26013

Conference Contributions

Mehraban, S., Malone, J., Lavery, N., Sullivan, J., Penney, D., & Brown, S. (2017). Increased Corrosion Resistance of Zinc Magnesium Aluminum Galvanised Coating through Germanium Additions. In ECS Transactions (pp. 1-15).
https://doi.org/10.1149/07530.0001ecst, SU Repository: https://cronfa.swan.ac.uk/Record/cronfa32175

Supervision

Untitled (current)

PhD

Other supervisor: Dr Jesus Ojeda Ledo
Zinc Coating Innovations for Superior Corrosion Protection (current)

PhD

Other supervisor: Prof James Sullivan
Continuous Temperature Measurement of Liquid Metal (current)

PhD

Other supervisor: Prof Cameron Pleydell-Pearce
“Optimisation of Next Generation Galvanising Pot Hardware” (current)

PhD

Other supervisor: Prof James Sullivan
Mechanical properties and electrochemical behaviour of Zinc Aluminium Magnesium Coatings (current)

PhD

Other supervisor: Prof Cameron Pleydell-Pearce
Development of advanced corrosion-resistant coatings with synthetic biology-inspired protein technologies (awarded 2023)

PhD

Other supervisor: Dr Geertje Van Keulen
Prevention of Corrosion in Cast Iron Water Mains (current)

EngD

Other supervisor: Prof James Sullivan
Development of Novel coatings for boron steel insurance in the hot stamping process (current)

EngD

Other supervisor: Prof James Sullivan
The failure mechanisms of organic coatings on zinc aluminium magnesium substrates under exposure to natural conditions and accelerated corrosion environments (current)

EngD

Other supervisor: Prof Cris Arnold

Other supervisor: Prof Geraint Williams
Development of Zn-Al-Mg alloys for galvanising applications (current)

EngD

Other supervisor: Dr Amit Das
Novel Galvanic Coatings for airport ground support equipment (current)

EngD

Other supervisor: Prof James Sullivan
Chromate-Free Corrosion Protection of Zn-Al Alloy Coated Steels (current)

EngD

Other supervisor: Prof Geraint Williams
Development of sensors and non-destructive analysis to determine the performance of coatings in construction (awarded 2023)

EngD

Other supervisor: Dr Eifion Jewell
Oxide Engineering on TCCT packaging steel. (awarded 2023)

EngD

Other supervisor: Dr Eifion Jewell
Addition of alloying agents to improve the performance of Zn/Al metallic coated steel. (current)

EngD

Other supervisor: Prof James Sullivan
‘Intrinsically delamination-resistant protective organic coatings for steel surfaces’. (current)

EngD

Other supervisor: Prof Geraint Williams
Galvanised Ultra High Strength Steels for Cold Formed Automotive Body in White Applications (awarded 2023)

EngD

Other supervisor: Dr Amit Das
High Temperature Corrosion Resistance of Nickel-Based Superalloys used in Industrial Processes. (current)

EngD

Other supervisor: Prof Mark Whittaker
The development of novel coating solutions for the improvement pre/post heat treatment performance properties of carbon steel conveyance tubes. (awarded 2024)

EngD

Other supervisor: Dr Amit Das
Fundamental study of filiform corrosion on novel automotive aluminium alloys (awarded 2024)

EngD

Other supervisor: Prof Geraint Williams
Developments in iron ore sintering using a laboratory scaled development platform (awarded 2023)

EngD

Other supervisor: Prof Cameron Pleydell-Pearce
Novel Coating Developments / Value-Adding Technologies«br /»«br /» For Automotive Ultra High Strength Hot Stamped Steels (current)

EngD

Other supervisor: Prof David Worsley
The Effects of Composition and Heat Treatment on the Microstructure and Performance of Cobalt-based Alloys for Molten Zinc Applications (awarded 2022)

EngD

Other supervisor: Dr Amit Das
ln-situ mapping of stress corrosion cracking using a scanning electrochemical probe (awarded 2024)

MSc

Other supervisor: Prof Geraint Williams

Taught Modules

EG-184 Mechanical Properties of Materials

The course provides a basic understanding of the relationship between the microstructure and the mechanical properties of metals. It will build on certain aspects of mechanical performance introduced in EG-180 (Introduction to Materials Engineering) and provide a reference point for supplementary modules in Years 2 and 3.
EG-213 Mechanical Properties of Materials

The course provides a basic understanding of the relationship between the microstructure and the mechanical properties of metals. It will build on certain aspects of mechanical performance introduced in EG-180 (Introduction to Materials Engineering) and provide a reference point for supplementary modules in later years of the study. Module Aims: to introduce the underlying principles of the mechanical properties of engineering materials.
EG-283 Mechanical Deformation in Structural Materials

Following on from the first year module "Mechanical Properties" this module provides further detail about the deformation characteristics of a wide range of engineering materials. The course aims to develop the understanding of topics taught in the first year module by application to high performance materials such as titanium and nickel. Further understanding of deformation and damage mechanisms is gained through targeted units on elasticity, plasticity, alloy strengthening, mechanics of materials, fatigue and creep. The knowledge provided then allows for topics such as methods of mechanical testing and additive layer manufacturing. The module then seeks to draw these topics together by considering application to three main material classes, metals, ceramics and composites.
EGA206 Aerospace Structural Mechanics and Materials

Building on Strength of Materials and Structural Mechanics 2(a), this module introduces the students to the stiffness method for structural analysis, followed by lectures covering stress concentration, fatigue, cracking and creeping of materials and how to design for these in the aerospace and automotive industry.
EGSM02 Interpersonal Skills for Engineers

The module will cover both presentation and written skills required for successful communication in enigineering. Presentations: Guidelines on making format presentations, considering attention span, visual aids, style, content and balance to ensure a memorable outcome. Preparation for one-on-one discussions, approaches to ensure successful meetings. Body Language: The influence of body language in communication both in formal presentations and in small group discussions. How to read body language in others, and modify your own body position to aid communication. Written: Guidelines on report preparation, including planning,structure and use of figures and tables. Preparation of an abstract, covering length, key issues and style for maximum effectiveness. Each candidate will prepare a detailed project plan covering background to the research, the scheduling of practical and other work, and milestone deliverables. This plan will be produced following: (i) attendance at specialist lectures covering issues of good practice in the conduct of research eg safety, procedures for laboratory work and data reporting/analysis; (ii) discussion with academic and industrial supervisors regarding technical/commercial issues associated with the specific topic; (iii) a review of the formal course units covering technical issues, personal and professional development and research skills. The overall report must demonstrate that each student relates relevant aspects of the training courses to their industry oriented research project.

Professor Dave Penney: Inaugural Lecture, 2019

Professor Dave Penney's Inaugural Lecture

Professor David Penney

Telephone number

Email address

Research Links

About

Areas Of Expertise

Publications

Research Highlights

All Research

Journal Articles

Conference Contributions

Supervision

Untitled (current)

Zinc Coating Innovations for Superior Corrosion Protection (current)

Continuous Temperature Measurement of Liquid Metal (current)

“Optimisation of Next Generation Galvanising Pot Hardware” (current)

Mechanical properties and electrochemical behaviour of Zinc Aluminium Magnesium Coatings (current)

Development of advanced corrosion-resistant coatings with synthetic biology-inspired protein technologies (awarded 2023)

Prevention of Corrosion in Cast Iron Water Mains (current)

Development of Novel coatings for boron steel insurance in the hot stamping process (current)

The failure mechanisms of organic coatings on zinc aluminium magnesium substrates under exposure to natural conditions and accelerated corrosion environments (current)

Development of Zn-Al-Mg alloys for galvanising applications (current)

Novel Galvanic Coatings for airport ground support equipment (current)

Chromate-Free Corrosion Protection of Zn-Al Alloy Coated Steels (current)

Development of sensors and non-destructive analysis to determine the performance of coatings in construction (awarded 2023)

Oxide Engineering on TCCT packaging steel. (awarded 2023)

Addition of alloying agents to improve the performance of Zn/Al metallic coated steel. (current)

‘Intrinsically delamination-resistant protective organic coatings for steel surfaces’. (current)

Galvanised Ultra High Strength Steels for Cold Formed Automotive Body in White Applications (awarded 2023)

High Temperature Corrosion Resistance of Nickel-Based Superalloys used in Industrial Processes. (current)

The development of novel coating solutions for the improvement pre/post heat treatment performance properties of carbon steel conveyance tubes. (awarded 2024)

Fundamental study of filiform corrosion on novel automotive aluminium alloys (awarded 2024)

Developments in iron ore sintering using a laboratory scaled development platform (awarded 2023)

Novel Coating Developments / Value-Adding Technologies«br /»«br /» For Automotive Ultra High Strength Hot Stamped Steels (current)

The Effects of Composition and Heat Treatment on the Microstructure and Performance of Cobalt-based Alloys for Molten Zinc Applications (awarded 2022)

ln-situ mapping of stress corrosion cracking using a scanning electrochemical probe (awarded 2024)

Taught Modules

EG-184 Mechanical Properties of Materials

EG-213 Mechanical Properties of Materials

EG-283 Mechanical Deformation in Structural Materials

EGA206 Aerospace Structural Mechanics and Materials

EGSM02 Interpersonal Skills for Engineers

Professor Dave Penney: Inaugural Lecture, 2019