e-PULSE2

The project focuses on the use of powder metallurgy (PM) to produce high-performance materials through spark plasma sintering (SPS). During sintering, the presence of Prior Particle Boundaries (PPBs) can hinder diffusion and bonding of the particles. PPBs significantly impact mechanical properties and fatigue resistance, two crucial factors for the aerospace industry. The use of pulsed direct current (DC) could be a solution to eliminate PPBs during SPS. However, the effectiveness of DC will depend on the selected material and the parameters used (amplitude, pulse frequency, etc.). In this project, we will concentrate on two materials used in aerospace: the nickel-based superalloy R77 and the Al1050A alloy, both of which containing carbides and/or oxides at PPBs. To determine the critical parameters leading to the elimination of PPBs during sintering in the presence of pulsed currents, we will conduct in parallel experimental work (WP1 and WP2) and modeling (WP3). Finite element modeling and instrumented SPS will quantify the in situ processes during sintering (temperature and current fields, resulting stress, etc.). Microstructural characterization and fatigue tests will identify samples with the best mechanical properties and without PPBs. This will enable us to optimize sintering parameters and validate computational models to make them predictive. Data from experiments and finite elements will be input for molecular dynamics simulations to simulate atomic mechanisms during sintering. Finally, we will perform a scale-up from the laboratory to the industrial scale to develop materials for the intended applications.