24-110 Development of Aluminium Alloys Dedicated to

Il y a 2 mois

Paris, France CNES - Centre National d'Etudes Spatiales Temps plein

Doctorat, 36 mois
- Temps plein
- Aucune expérience exigée
- Maitrise, IEP, IUP, Bac+4
- Mechanical and thermal engineering

**Mission**:
This thesis focuses on the L-PBF (Laser Powder Bed Fusion) process, which is an additive manufacturing process involving the successive fusion of layers of powdered material using a laser. This process is characterized by very short interactions between the raw material (powder) and the laser, resulting in very rapid solidification and cooling rates. The result is a complex microstructure with, in particular, the appearance of strong supersaturations in the matrix, the precipitation of hardening phases and the formation of dislocations due to thermal strain hardening. These phenomena occur simultaneously, resulting in alloys with remarkable hardenability in the as-built state.

The main challenge is to be able to understand the fundamental phenomena at the microstructural scale and in particular the mechanical behavior of the part in the as-built state. Indeed, the metallurgical states induced by this manufacturing process are characterized by microstructural heterogeneities at several scales, from grain morphology to the chemical nature and size of the nanometric precipitates that harden the material. Understanding the consequences of these microstructural heterogeneities on the mechanical response of these alloys produced by L-PBF constitutes the main issue of this thesis.

The binary Al-Fe system is chosen because alloys hardened by small iron-based precipitates have better mechanical behavior at high temperatures than conventional aluminium alloys. A particular feature of this work is to directly control, through the processing parameters, the specific characteristics of the metallurgical organization that give the Al-Fe system its remarkable mechanical properties. To do this, we need to be able to understand the impact of each of these parameters (laser power, feed rate, temperature of the manufacturing plate) on the microstructure obtained in the as-built state. This work will therefore investigate the effect of different L-PBF processing parameters on the microstructure and mechanical response of the material.

The thesis work will involve several complementary experimental and modelling aspects.

A detailed characterization of the as-built microstructure by scanning and transmission electron microscopy (SEM and TEM) and X-ray diffraction (XRD) will be carried out on several samples with different Fe contents. Based on these initial results, different manufacturing parameters will be tested. Particular attention will be paid to the effect of local chemistry, through comparison of chemical analyses carried out by transmission electron microscope with measurements obtained by Atom Probe Tomography (APT). Knowledge of this local chemistry is essential, as the iron content of the matrix is a key hardening mechanism. The mechanical response of the material will be studied at the macroscopic scale, by means of tensile and creep tests, and at the scale of the melt pool, through tensile tests in-situ in a SEM, allowing the deformation fields to be monitored by digital image correlation, in order to analyze the differences in local behavior due to the underlying microstructure.

The aim of the modelling is twofold. Firstly, to propose a phenomenological hardening model based on the microstructural properties of the material. The parameters of this model will be deduced from microstructural characterizations and local behavior measurements. The model will be tested on all available samples to validate the proposed formalism and refine our understanding of the role of each of the microstructural element. The model will then be used to establish the relationship between the L-PBF manufacturing parameters and the degree of hardening of the material. In addition, to fully understand the effect of microstructural heterogeneities on macroscopic behavior, full-field calculations will be performed using simple elasto-visco-plastic laws, and the results will be compared with those obtained from in-situ micromechanical tests in the SEM.

=================

**Profil**:
Master in mechanics and/or materials science

**Laboratoire**:
ONERA

**Message from PhD team**:

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