In comparison to traditionally fabricated steels that can undergo extensive processing to produce a complex-shaped component, the powder metallurgy (PM) technique can provide a more efficient approach as it is capable of producing intricately-shaped components that require little to no additional processing and machining [1], [2]. A key factor in being able to do so pertains to quenching and utilizing an appropriate quenching agent that can provide dimensional stability to the part being quenched [3], [4]. To ensure that a PM component can perform equally well when being quenched by a quenchant of reduced cooling capability, the PM component should be if not more, then just as hardenable. Steel hardenability can inevitably be improved with the increase of overall alloying content [5], however, if overall alloying content is to be kept at a minimum, the concept of lean PM steel design is one worth investigating; where a lean steel entails that each and every alloying addition is utilized to its maximum potential. This study evaluates the homogenization behaviour of alloying elements in PM steels during sintering as well as the efficiency of wide-spread industrial practices involving the use of various master alloys and ferroalloys, and investigates the realm of liquid phase sintering to understand and optimize the homogenization behaviour of alloying elements and mechanical properties of PM steels. In the context of this work, multi-component master alloys contain at least three of non-ferrous metals as alloying elements and ferroalloys are master alloys containing iron in addition to typically a maximum of two other non-ferrous alloying additions. Part one of this study discusses a combination of thermodynamic software (DICTRA and Thermo-Calc), incremental sintering experiments and scanning electron microscopy (SEM) - wavelength dispersive spectroscopy (WDS) that were used in order to form a deeper understanding of the homogenization behaviour of alloying elements within PM steel during sintering. Electron microscopy analyses on partially and industrially sintered components provide elemental maps to track the evolution of alloying elements as they relax to homogeneity. Electron microscopy analyses for this portion of the study were conducted on an industryproduced automotive component that was sectioned and sintered industrially as well as experimentally at 1280°C for 30 minutes and 13.4 hours. DICTRA simulations carried out for this research provide a 1-D insight into the evolution of concentration profiles and phases throughout various sintering times for systems involving Cr, Mn, C and Fe. DICTRA simulation results of alloying sources were studied alongside alloying element profiles obtained by compiling point quantification from wavelength dispersive spectroscopy maps for the sintered automotive component. Computational results provided conservative, semi-quantitative recommendations on optimal alloy addition forms that lead to an improvement in homogenization. Part two of this study involves the approach of fabricating and testing multi-component master alloy additions. As these materials are widely employed in PM and are typically fabricated by solidification, their states are non-equilibrium and therefore have regions containing phases precipitating in the beginning of freezing which have higher melting temperatures than regions with phases forming later on. During heating, it is hypothesized that Scheil’s solidification path backtracks and as a result, a fraction of liquid in the ferroalloy can be estimated at sintering temperature. If the fraction is significant, the utilization of this ferroalloy implies liquid phase sintering. Through a combination of Thermo-Calc and Fortran softwares, multi-component ferroalloys with promising compositions were discovered in Fe-C-Cr-Mn, Fe-C-Cr-Mn-Ni, FeC-Mn-Mo, Fe-C-Mn-Mo-Ni and Fe-C-Cr-Mn-Mo-Ni systems for low temperature liquid phase sintering. Those of the Fe-C-Cr-Mn-Mo, Fe-C-Cr-Mn-Mo-Ni and Fe-Mn-Mo-Ni system were fabricated and tried in practice. Compositional maps and mechanical properties of PM steels made with variations of this specially tailored multi-component master alloys were compared with those for which traditional alloy additions were used. / Thesis / Master of Applied Science (MASc)

De nos jours, une des stratégies pour améliorer les propriétés des brasures sans plomb est d'introduire en petites quantités certains éléments d'alliage. Dans notre étude, deux nouveaux types de brasures, dénommés Innolot et SAC-Bi et dont l'utilisation dans diverses applications électroniques augmente, sont caractérisées. En particulier, l'effet des éléments Ni, Sb et Bi sur les propriétés mécaniques est analysé. L'étude vise également à évaluer l'influence des facteurs de sollicitation, du vieillissement en température sur la réponse des matériaux et leurs évolutions microstructurales. A cet effet, une machine permettant de réaliser des essais de micro-traction sur éprouvettes miniatures a été conçue et fabriquée. Les sollicitations qu'elle permet d'appliquer sont multiples (traction, cisaillement et cyclage) et des conditions en température et en vitesse de déformation peuvent être imposées lors de l'essai. La fabrication des éprouvettes nécessaires aux essais a également été entreprise dans cette étude afin d'avoir un matériau similaire à celui issu du process industriel et de disposer d'une géométrie adaptée au type de caractérisation souhaitée (éprouvettes massives, à simple recouvrement, etc.).Après ces étapes préparatoires, des tests ont été réalisés sous sollicitations de traction, cisaillement, fluage et fatigue en faisant varier les conditions d'essais. Le premier objectif a été l'identification du comportement des brasures, y compris en prenant en compte l'effet du vieillissement. Ces données ont permis ensuite de réaliser des simulations thermo-mécaniques sur les matériaux utilisés sous forme de joints de brasure dans un module de puissance sous cyclage thermique. Les analyses de microstructure (SEM/EDS et EPMA) faites par la suite ont montré le rôle des éléments d'alliage (Ni, Sb et Bi) sur les performances mécaniques des brasures en termes de résistance, limite élastique et rigidité. Le rôle des facteurs d'essai, comme la température, la vitesse de sollicitation et la durée de vieillissement, a également été mis en évidence au niveau des propriétés obtenues et des changements dans la microstructure. Il a été établi que l'élément Sb permet de favoriser le durcissement par écrouissage des brasures, tandis que l'ajout des éléments Ni et Bi permettent un raffinement de la microstructure. Les essais ont aussi permis d'identifier les 9 paramètres de la loi d'Anand par une procédure numérique s'appuyant sur les données de traction et de cisaillement, permettant ainsi de réaliser des simulations par éléments finis. Ces dernières suggèrent un meilleur comportement à la fatigue pour la brasure Innolot qui bénéficie est effets favorables des additifs. / Nowadays, one of the strategies to improve the reliability of lead-free solder joints is to add minor alloying elements to solders. In this study, new lead-free solders, namely InnoLot and SAC387-Bi, which have begun to come into use in the electronic packaging, were considered to study the effect of Ni, Sb and Bi, as well as that of the testing conditions and isothermal aging, on the mechanical properties and microstructure evolution. A new micro-tensile machine are designed and fabricated, which can do tensile, compressive and cyclic tests with variation of speeds and temperatures, for testing miniature joint and bulk specimens. Additionally, the procedure to fabricate appropriate lap-shear joint and bulk specimens are described in this research. The tests, including shear, tensile, creep and fatigue tests, were conducted by micro-tensile and Instron machine at different test conditions. The first study is to characterize, experimentally, the mechanical behaviors and life time of solder joints submitted to isothermal aging and mechanical tests. The second goal of the project is to perform thermo-mechanical simulations of IGBT under thermal cycling. The experimental results indicate that, with addition of Ni, Sb and Bi in to SAC solder, the stress levels (UTS, yield stress) are improved. Moreover, testing conditions, such as temperature, strain rate, amplitude, aging time, may have substantial effects on the mechanical behavior and the microstructure features of the solder alloys. The enhanced strength and life time of the solders is attribute to the solid hardening effects of Sb in the Sn matrix and the refinement of the microstructure with the addition of Ni and Bi. The nine Anand material parameters are identified by using the data from shear and tensile tests. And then, the obtained values were utilized to analyze the stress-strain response of an IGBT under thermal cycling. The results of simulations represent that the response to thermal cycling of the new solders is better than the reference solder, suggesting that additions of minor elements can enhance the fatigue life of the solder joints. Finally, the SEM/EDS and EPMA analysis of as-cast, as-reflowed as well as fractured specimens were done to observe the effects of these above factors on the microstructure of the solder alloys.