INTERNSHIP - R&D Mechanical / Physical Metallurgy Engineer
France, Auvergne-Rhône-Alpes, Voreppe
December 1st, 2023
INTERNSHIP - R&D Mechanical / Physical Metallurgy Engineer (all genders)
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.
In the context of a 6-month internship, C-TEC is partnering with the research instiitue MPIE located in Düsseldorf on recruiting an engineer intern in the field of Mechnical and/or Physical Metallurgy to work on the following subject : On the use of a Phase Field method for Damage coupled with Crystal Plasticity for a better understanding of the role of texture and intermetallic particles on bending performance of Al alloys for automotive
Location: the student will be employed and hosted by MPIE, Düsseldorf (Germany)
Due to its low density, aluminium (Al) is a key material for sustainability as it allows lightweighting. In order to decrease the CO2 emissions associated with its production, it is required to massively use recycled aluminium, meaning remelting Al scrap to make new ingots. However, switching from primary synthesis (bauxite reduction) to secondary synthesis (scrap melting) often leads to increasing impurities, the main one being iron in aluminium. Such contaminants may impact the performance of the current alloys in terms of ductility/formability, especially on sharp edges. It is the case of automotive outer panels that are bent around the inner part after stamping. The project of master thesis is linked to microstructure optimization, and especially crystallographic texture (meaning grain orientations and their spatial arrangement) and intermetallic particles. Thus, it is key to identify how microstructure could be tuned to maintain current product performance, while increasing recycled content. For that, Constellium C-TEC is working with the Max-Planck-Institute für Eisenforschung (Düsseldorf, team of Pr. Franz Roters) who has developed an open-source software, Damask, allowing to model the mechanical behavior of grains aggregates under different loading types. More recently, damage has been integrated within the crystal plasticity calculations thanks to a phase field method. The goal of this master thesis would be to test this new modeling method to predict damage development in microstructures representative of aluminium alloys with different impurity contents.
The objective of the project is thus to compute damage evolution at the grain scale of ductile materials such as Al alloys and to evaluate the possibility of extension of this methodology to higher scales.
The project has several components:
- Literature review to understand how the Phase Field method works and highlight research items having already tackled the application of this method for ductile materials.
- Literature review to identify failure mechanisms in bending, analyze existing results and transposing these results to define a representative loading to apply at the grain scale.
- Using Damask software to achieve the objective
- Study the impact of the texture and intermetallic-related features (size, morphology, spatial distribution) on the response
- Analysis and synthesis of the results, report writing and presentation to the team
The position will be located at the research institute (MPIE, Düsseldorf) within an international team of students and researchers under the supervision of Franz Roters. MPIE is a cutting-edge research laboratory with extensive experience in both materials modelling and characterization, used to tackle complex challenges in relation with industrial partners. Regular contact with Constellium research engineers with expertise in metallurgy and mechanics together with some stays at the industrial research center in France will be organized.
Education level: Engineering school or Master of Science
Competencies (technical & soft skills requirements):
- Good knowledge in mechanics and physical metallurgy
- Motivation for modeling work, previous FE modeling experience would be a plus
- Strong capacity to post-treat and analyze a significant amount of data
- Serious, autonomy, critical mind and creativity
- Candidate interested in research and development (possibility to pursue with a PhD)
- Good English level compulsory, both written and spoken. German language skill is a strong plus.