Main research questions:

RQ1.1: What are the effects of PCS on critical properties like strength, ductility, fatigue, corrosion and conductivity?

RQ1.2: Which accumulated element, or combination of elements, are responsible for the property changes, and at what critical concentrations?

RQ1.3: What are the changes in microstructure caused by the altered alloy chemistry, and how do this relate to the thermo-mechanical process?

RQ1.4: How can we integrate advanced experimental techniques and numerical methods to better understand and mitigate the effects of PCS?

RQ1.5: How can FAST Virtual Lab be capable of predicting the relevant properties of PCS alloys solely based on chemical composition and thermo-mechanical history?

Approach and methodology:

A multi-physics approach across material scales from the nanoscale up to meso-scale, integrating both experimental and simulation methods. This includes TEM and SEM measurements, X-ray tomography, and mechanical tests (both ex-situ and in-situ) combined with numerical methods ranging from DFT/MD to CPFEM analyses of relevant microstructural features.

Research Tasks:

T1.1: Experimental investigations will quantify how varying fractions of PCS affect yield strength, ultimate tensile strength, and work-hardening in selected aluminium alloys. Based on these investigations, we will develop a Strength module for the virtual laboratory. This module will predict relevant properties using the chemical composition and thermo-mechanical history of the alloy as input.

T1.2: Numerical methods will be developed to predict crack initiation and propagation in HPDC and wrought alloys. Additionally, we will create a Ductility module for the virtual laboratory, which will predict the ductility of an alloy based solely on its microstructure.

T1.3: This task will map the effect of PCS on fatigue performance and corrosion resistance for selected alloys by combining advanced microscopy and lower-scale simulations. Mitigation techniques will be proposed and applied to these alloys. Finally, an evidence-based Durability module for the virtual lab will be developed.

T1.4: We will quantify how PCS alters electrical conductivity in relevant alloys. A Conductivity module for the virtual lab will be developed.

Main expected outcomes (OU):

OU1.1: Identification of properties of high PCS content alloys, and their effects, across relevant length- and timescales.

OU1.2: Physics-based and data-driven digital toolkits capable of predicting critical properties (input Virtual Lab).

OU1.3: 4 PhD candidates are connected to WP1.