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This project is devoted to the net shape manufacturing of two intermetallic materials by means of an emerging powder compaction technique called SPS (Spark Plasma Sintering). Application of this technology to high performance intermetallics that are difficult to manufacture or to form using conventional techniques will allow their cost-effective introduction in gas turbines or in car engines. These systems are niobium silicide-based materials and titanium aluminides. These low density materials have great potential to increase thrust-to-weight ratios and improve fuel efficiency of gas turbine aero-engines, thus reducing drastically the amount of emissions and contributing to a cleaner environment. These materials are then qualified to meet a range of applications identified by the aero-engine manufacturers, for temperatures ranging from 700°C to 1000°C. Furthermore, using TiAl alloys to manufacture car engine exhaust valves that are withstanding temperatures of 600 to 800°C induces a reduction in fuel consumption (reduced mass and inertia, higher performance) with respect to current high density alloys (steels, superalloys). The components selected to validate the SPS technology will be of increased complexity throughout the project: exhaust valve (axisymmetric 2D) and seal segment (similar to a curved plate, nearly 2D), then turbine blades (3D). As a preliminary stage on small-scale samples, full potentialities of the SPS technique will be delimited by varying the main process parameters for both intermetallic alloy systems, associated with a thermo-metallurgical and physical modelling. This model will be an essential tool to determine the processing conditions and to design the tools needed for complex shape component manufacture. Attempts to achieve an appropriate balance of low and high temperature mechanical properties, or even oxidation resistance, will be made through the utilisation of ultra-refined and/or homogeneous microstructures that can be tailored by SPS. Following these structural optimisations, industrial up-scaling and complex net shaping by SPS will become the major challenges in view of the fabrication of full-scale aeroengine components. This up-scaling will be achieved in two steps, first on large scale two-dimensional components of simple geometry, then on large scale three-dimensional complex shaped components, but each time with the help of numerical simulations. Each step will be validated on microstructural criteria and through basic mechanical characterisations. The use of SPS to manufacture bi-material components or to join identical materials will also be evaluated. The goal will be to manufacture, ideally in a single SPS step, a structural component using either two powders, or a bulk material associated to a powder. The joining quality will be characterised through microstructural analyses and mechanical tests.
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