Internship R&D - Modelling and Optimizing Quench Sensitivity in Aluminium Alloys

C-TEC INTERNSHIP OFFER 

Constellium is a world leader in the development and manufacture of high value-added aluminum products and solutions for a wide range of markets and applications, focusing in particular on aerospace, automotive and packaging. Constellium also has nearly 12,000 employees worldwide.We are committed to minimizing the environmental impact of our operations and improving the life cycle footprint of aluminum throughout the value chain.

In our company, safety is essential, it is one of our core values without compromise. Our Research and Technology Center, C-TEC Constellium Technology Center, based in Grenoble (Voreppe – 38) employs about 240 people. 

By joining our company, you will discover a multicultural company (over 20 nationalities) which is committed to diversity and the well-being of its employees.

Your mission : Understanding the effects of deformation on the quench sensitivity and precipitation kinetics in aluminium alloys

Context

Based within the metallurgy team and working for the Transportation, Industry & Defense (TID) market at C-TEC, the mission of this internship is to contribute to the fundamental metallurgical understanding required to develop the next generation of aluminium alloys for transport applications. Quench sensitivity is a phenomenon in age-hardenable aluminium alloys whereby a loss in strength is observed if cooling after solutionizing occurs too slowly (due to the quench media used; water vs air, or due to the plate thickness). Extensive work exists in this domain for many alloys whereby Time-Temperature-Property (TTP) curves are created to evaluate the critical quench rates of alloys as to limit property loss. However, there is a lack of data and understanding available on the effect of deformation during cooling, like that observed during hot rolling processes on the quench sensitivity. This internship strives to remove that knowledge gap by testing different aluminium alloys (2xxx, 6xxx, 7xxx) and evaluating the difference in the quench sensitivity with and without the presence of deformation at elevated temperatures. 

The project has several components

• Perform bibliographic research to become aware of the state of the art of factors influencing the quench sensitivity of different aluminium alloy, including both empirical and analytical models as well as methods to evaluate the quench sensitivity of aluminium alloys
• Assist in the preparation and testing of different (2xxx, 6xxx, 7xxx) series of aluminium alloys to evaluate their baseline and deformation-modified quench sensitivities
• Perform mechanical polishing, hardness testing and conductivity measurements to generate the required data for further testing and model generation
• Develop and implement quench factor analysis (QFA) to estimate the final properties of the different alloys tested
• Use Constellium’s Calphad models to validate experimental observations and use experimental observations to improve the Calphad models
• Establish and propose new compositions and processes, based on learnings during the internship that should be trialed at the lab scale to prove model and simulation robustness

The role of the intern will consist, after a first phase of training in our trades and tools to first work with the lab technicians to perform the various thermal and mechanical tests required to generate a section of the TTP curves in a selection of different Constellium alloys. The next steps will be to measure the hardness and conductivity of the different alloys and conditions and to compile the generated data in an organized manner. Next, the generation of the TTP curves with and without deformation will be performed along with the extraction of the parameters to perform QFA. With the help of the engineers, simulations of the complex thermal treatments of the plant will be applied to the evaluated alloys to estimate the potential performance if they were to be made at the industrial scale. If possible, working with the core competency team at CTEC, refining and adapting the existing metallurgical models will be done. Based on the results and predictions, lab-scale trials will be performed where close control over the thermal cycles can be made validate the models. Based on the models, simulations will be made to decide if industrial trials are warranted and/or if modifications to the alloy and/or processing route would lead to improved properties. Weekly and monthly meetings can be expected to take place within a larger team (program manager, business unit, plants, etc) to share results and give updates on the overall progress of the internship.

Profile 

Education level : Bac +5

Engineering school and/or degree / option required Materials and metallurgical engineering

Competencies & technical & soft skills requirement :

• Good metallurgical understanding of the production steps of sheet metal is required
• An appreciation for bibliographic research and modeling is necessary
• An understanding of solubility, precipitation and quench sensitivity
• Ability to work independently but also as part of a team
• Use critical thinking to explain the observations of different experimental design
• Ability to analyze, synthesize and present results requiring various levels of technical detail (high-level vs. research focused)
• Attraction to working in a fast-paced environment with a multi-national team in both English and French
• Actively work in a safe manner and follow standard operating procedures and adhering to Constellium’s required safety practices
• Strong skills in English (B2 minimum) and French (B2 minimum), both written and spoken