Hypersonic flight at a speed greater than Mach 5 (1715 ms-1) requires materials that can withstand temperatures up to 3000°C, high heat flux, rapid heating and disassociated reactive oxygen in the extreme environment of space and during re-entry. A number of advanced ceramic materials have melting points over 3000°C, of which the refractory metal carbides and borides are of main interest due to their excellent thermal conductivity from room temperature to over 2500°C, good chemical stability and ablation resistance at high temperatures. These materials are classified as ultra-high-temperature ceramics (UHTCs). Among the family of UHTCs, ZrB2 and HfB2 are reported as the most promising candidates to be used as thermal protection systems (TPS) for the nose tip and sharp leading edges. However, the issue of using monolithic ZrB2 and HfB2 is the phase transformation of ZrO2 and HfO2 oxide by-products at elevated temperature, leading to a volume change that results in cracking of the formed oxide scale. Hence, it is necessary to use dopants to stabilize the oxidation products of ZrB2 and HfB2 in-situ and to minimise the transformation induced cracking and thus improving the oxidation resistance. This research is focused on introducing dopants, such as Y and Ta into HfB2 and to understand its effect on the oxidation behaviour of HfB2 based UHT ceramics. The primary objectives were to: (a) Synthesize sub-micron pure and doped HfB2 powders; (b) Sinter the HfB2 based ceramics to achieve relative density > 95% (i.e. with close porosity); (c) Assess the effect of dopants on the oxidation resistance of HfB2 ceramics at high temperatures. Sub-micron pure HfB2 powder of ~200 nm was synthesized by a modified sol-gel approach combined with subsequent carbothermal reduction process using hafnium tetrachloride, boric acid, and phenolic resin as the starting materials. HfC and residual carbon were found to be the main impurity phase, owing to the lack of removal of carbon-containing species in the argon atmosphere during the heat treatment. Therefore, a precipitation approach was developed to transfer hafnium tetrachloride into hafnium hydroxide during the mixing stage to get rid of the Cl- and carbon-containing functional groups. Based on the detailed study of the formation mechanism of HfB2, it was found that the particle size of the HfB2 powders was decided by the particle size of the starting Hf source. Although the powders were slightly coarser (~400-800 nm) from the precipitation approach, importantly phase-pure HfB2 was formed at the same furnace heating conditions (1600°C/2 hrs). The precipitation method was also used to prepare doped HfB2 powders as the homogeneity of the dopants (TaB2, Y2O3) could be improved by controlling the pH values at ~8.5 to achieve the simultaneous precipitation of the dopants and HfB2 precursors. As a result, (Hf,Ta)B2 solid solution was prepared successfully at the temperature of 1600°C. Spark plasma sintering (SPS) was used to densify the pure and doped HfB2 powders. The optimized density achieved was around 97% at 2150°C without the use of any sintering aids and the addition of TaB2 slightly improved the sinterability of the HfB2 based powders due to the formation of the (Hf,Ta)B2 solid solution. The sintered density of commercial micron HfB2 powders (Treibacher) was only 94% in the same condition, and the resultant grain size (5-10 μm) is also significantly larger than that from synthesized HfB2-based ceramics (2-6 μm). The oxide impurities, such as HfO2 and B2O3, on the surface of the fine HfB2 based powders were attributed as the main reason for inhibiting further densification. The oxidation behaviours of the HfB2 based ceramics were investigated via both static oven oxidation and oxyacetylene torch testing. In low and intermediate temperature regime ( < 1600°C), it was indicated that the addition of dopants didn't significantly improve the oxidation resistance as the glassy B2O3 was the critical factor controlling the oxygen permeation rate. However, in the high-temperature regime ( > 1600°C), it was found the oxidation product was mainly tetragonal HfO2, which was stabilized by the Ta-dopants at temperatures well below the HfO2 phase transformation temperature. Therefore, the cracking and volume change due to phase transformation can be avoided and in return, oxidation resistance was improved at high temperature, which should be beneficial for the application of these materials in hypersonic aviation.

Le frittage est une étape clé de l’élaboration des pastilles de combustible nucléaire de type UOx et MOx (oxyde mixte (U,Pu)O2) utilisées dans les réacteurs à eau pressurisée. Le premier stade de ce procédé, qui consiste en l’élaboration de ponts entre les grains et conduit à la consolidation des matériaux, est jusqu’à présent principalement abordé par simulation numérique. Les modèles utilisés pour la description théorique de cette étape du frittage sont alors généralement constitués deux grains sphériques en contact. Afin de réaliser les premières observations expérimentales du stade initial du frittage de matériaux céramiques d’intérêt pour le cycle du combustible électronucléaire et d’en compléter les approches numériques, des poudres d’oxydes de lanthanides (CeO2) et d’actinides (ThO2 et d’UO2) de morphologie contrôlée ont été étudiées par microscopie électronique à balayage en mode environnemental lors de traitements thermiques à haute température (MEBE-HT).Dans un premier temps, des protocoles conduisant à la synthèse de microsphères d’oxydes de lanthanides ou d’actinides ont été développés, et les poudres obtenues entièrement caractérisées. Il a ainsi été possible d’obtenir pour l’ensemble des composés étudiés des systèmes similaires à ceux modélisés. Par la suite, le MEBE-HT a été utilisé comme principal outil d’investigation pour le suivi in situ de ces composés. Ainsi, l’étude de l’évolution morphologique de microsphères isolées a tout d’abord confirmé leur caractère polycristallin. Le traitement thermique conduit alors à une diminution progressive du nombre de cristallites sous l’effet de différents mécanismes (réarrangement mécanique, diffusion) dont l’énergie d’activation a été évaluée. Pour les systèmes constitués de deux microsphères de CeO2 ou de ThO2 en contact, les micrographies collectées ont permis d’observer l’évolution de paramètres tels que la taille du pont, la taille des grains et la distance entre leur centre au cours du traitement thermique. Des procédures de traitement d’images ont ensuite été appliquées pour aboutir à des données cinétiques quantitatives. Les mécanismes mis en jeu, tels que le réarrangement des plans cristallins et la diffusion de matière, ainsi que les énergies d’activation correspondantes, ont en outre été identifiés. De plus, la loi de croissance des ponts, qui permet de décrire les cinétiques d’avancement du frittage, a été utilisée pour déterminer le mécanisme de diffusion prépondérant lors du traitement thermique. L’influence de différents paramètres sur l’avancement du frittage a enfin pu être mise en évidence. A titre d’exemple, l’effet de la polycristallinité des grains sur les mécanismes et les cinétiques de frittage a été étudié en travaillant en parallèle sur des grains poly- et monocristallins, puis en comparant les données expérimentales avec celles issues de modélisation. Enfin, la méthodologie développée pour l’étude de CeO2 et ThO2 a été transposée au composé d’intérêt UO2. Dans ce cas, les données précédemment décrites ont également été complétées par une première approche de l’influence de l’atmosphère utilisée lors du traitement thermique. / Sintering is a key step in the elaboration of UOx and MOx (U/Pu mixed oxide) nuclear fuels pellets used in the pressurized water reactors. The first step of this process, which consists in the elaboration of a neck between the grains and led to the consolidation of the material, is generally described through numerical simulation. The models used for the theoretical description of this step are generally constituted by two spherical grains in contact. In order to perform the first experimental observations of the initial stage of sintering of ceramics materials of interest for electronuclear fuel cycle and to complement the numerical approaches, samples of lanthanide (CeO2) and actinides (ThO2 and UO2) dioxides with controlled morphology were examined by environmental scanning electron microscopy during heat treatment at high temperature (HT-ESEM).First, the protocols leading to the synthesis of lanthanides and actinides oxides microspheres were developed, and the powders obtained characterized. It was thus possible to obtain, for all the compounds studied, systems similar to those generally modeled. HT-ESEM was then used as the main investigation tool for the in situ study of the first stage of sintering of these compounds. The study of the morphological modifications occurring in isolated microspheres first confirmed their polycristalline character. Indeed, heat treatment led to a progressive decrease of the crystallites number included inside the grains through different mechanisms (oriented attachment, diffusion), whose activation energy was evaluated. For the systems constituted by two CeO2 or ThO2 microspheres in contact, the ESEM micrographs allowed to observe the evolution of several parameters during heat treatment, such as neck size and grain size as well as distance between the grains center. Images processing methods using custom software were then applied in order to determine the quantitative kinetic data. The mechanisms involved, such as the rearrangement of crystalline planes and the matter diffusion, and the corresponding activation energies, were also identified. Furthermore, the law of neck growth, which allows one to describe the evolution of sintering degree, was used to determine the prevailing diffusion mechanism during heat treatment. The influence of various parameters on the sintering degree was also highlighted. For example, the influence of grains polycristallinity on sintering mechanisms and kinetics was particularly investigated study by working in parallel with polycristalline and single crystal grains, then by comparing the experimental results with data coming from modeling. Finally, the methodology developed for the study of CeO2 and ThO2 was transposed to the compound of interest UO2. In this case, the data previously described were complemented by a first approach of the influence of atmosphere used during the heat treatment.

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