Internship - R&d Engineer - Impact of Intermetallic

Il y a 2 mois

Voreppe, France Constellium Temps plein

**C**-TEC RECRUTE**

**INTERNSHIP - R&D ENGINEER F/H/X**

**I**mpact of intermetallic phases on the formability of recycling-friendly aluminium alloy**

**Key words**:Mechanical and microstructural characterization,, Hot -rolling simulation, Aluminium alloy, End-of-life recycling

**Context**:
Due to its low density, aluminium (Al) is a key material for sustainability as it allows lightweighting. In the transportation industry, this means fuel consumption reduction and thus lower CO2 emissions, or increased autonomy for electrical vehicles. However, producing primary Al from bauxite ore is very **energy intensive**, especially the electrolysis step in which alumina oxide is refined and transformed into metal aluminium. So, it is interesting to **massively use recycled aluminium**, meaning remelting Al scrap to make new ingots. Indeed, only 5% of the energy required to produce primary Al is needed to remelt used Al. In principle, Al can be recycled endlessly. However, only one third of Al produced today is made from scrap, resulting in significant greenhouse gas emissions. Increasing this ratio in the coming decades and operating a significant shift from primary synthesis (ore reduction) to secondary synthesis (scrap melting) require **designing new alloys**, able to **tolerate more impurities**. The project of the internship is linked to the development of a new alloy grade permitting to absorb a significant amount of automotive End of Life (EoL) scrap. This comes hand in hand with a change in the microstructure of the material and a strong increase of the number of secondary phases due to contaminants brought by the recycling loop. These microstructural changes may lead, without adapted process adjustment to decreased ductility / formability.

**Objectives**:
The objective of this project is to investigate how the different **intermetallic phases behave during both the internal transformation schedule (especially hot and cold rolling) and the subsequent forming operations at the customers (deep drawing, **plane strain tension, hemming) The final goal is to optimize the process and find ways to mitigate the detrimental impact of these phases. In addition to industrially produced material, hot rolling simulations will be performed at C-TEC with a thermo-mechanical equipment (Servotest) to simulate the hot deformation and study the particles evolution at different steps of the production. Particles fracture and particle/matrix decohesion will be characterized and quantified using optical and electron microscopy. From these observations a **phenomenological model for damage evolution in this type of alloys will be proposed.**

The project has several components:

- Literature review of the different fracture mechanisms governing the material properties of a two phases material (load transfer from matrix to particles during deformation, fracture of second phase particle and crack initiation back into the metal)

Prototyping of different process conditions at the lab scale (variations in composition and/or transformation schedule)
- Microstructural characterization of the intermetallic phases before and after deformation for both high temperature and room temperature deformations (optical microscopy and scanning electron microscopy with EDX for chemistry measurements)
- Identification of fracture mode and crack initiation sites for the different loading states at room temperature (fracture surfaces analysis by SEM)
- Analysis and synthesis of the results through a model for damage evolution, report writing and presentation to the team

The intern will be part of a R&D team of engineers working on the development of recycling-friendly alloys. The internship work is strongly experimentally oriented.

**Profile**:
**Education level**:
**Engineering school**.... and/or degree / option required...**

**Competencies & technical & soft skills requirement**:

- Good knowledge in physical metallurgy
- Motivation for experimental work
- Strong capacity to post-treatment and analyze a significant amount of data
- Serious, autonomy, critical mind and creativity
- Good English level, both written and spoken

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