Die wall friction and influence of some process parameters on friction in iron powder compaction

Abstract

The coefficient of friction is a system response parameter, which is affected by a number of parameters such as normal load and sliding distance. Experimental results describing the influence of these parameters are presented in this study. These parameters have a crucial role in the modelling of the compaction process and also provide an in depth understanding of the mechanism of friction in powder compaction. The powder surface characteristics change continuously during the pressing, making friction measurement quite difficult. An attempt has been made to identify and separate the powder behaviour during compaction. The experimental results show that the plastic deformation of the surface in contact with the die wall occurs at an early stage of the compacting. At densities above 5 g cm³ the plastic deformation is completed and the variation of the coefficient of friction is minimal. It has been observed that most changes of the powder surface occur at low densities. The nature of the friction has also been discussed.     

A study of compaction of composite particles by multi-particle finite element method

We study the compaction of composite mixture of soft and hard micro-/nano-size particles using multi-particle finite element method. In this method, each particle is fully discretized into finite element mesh. Local non-uniform contact deformation and non-uniformity stress chains transmitted through the composite are well illustrated. In this work, we focus on the effect of inter-particle friction and volume fraction of hard particles on compaction pressure. Results of closed die compaction of 400 two-dimensional monosize spherical particles of zero and 40% volume fraction hard particles are presented. The results show that compaction pressure increases with inter-particle friction and volume fraction of hard particles. The predicted compaction pressure curves are in good agreement with experimental data and other models.     

Size Ratio Effects on Particle Contact Evolution at Uniaxial Powder Compaction

Cold compaction of composite powders has been analyzed using a discrete element method (DEM). Powder aggregates consisting of up to approximately 10,000 particles and formed by two powder populations with known material strength and size ratios have been compacted both isostatically and uniaxially (die compaction). The particles were assumed constitutively to be perfectly plastic or rigid and as a result, local contacts between the particles were described by a linear force-displacement relation given by previous in-depth analyses of spherical indentation problems. Particular emphasis has been placed on investigating the particle contact evolution at die compaction and to compare the results with previous ones pertinent to the isostatic case. Consequently, the predictive capability of the fundamental assumptions frequently used in theoretical analyses of compaction problems is determined for a uniaxial situation. The main conclusion is that size ratio effects are substantial at die compaction and when such features are present, theoretical predictions overestimates the (average) number of contacts per particle. It was also found that the mechanical behaviors at isostatic and die compaction are very similar even though die compaction values are slightly higher at high values on the relative density of powder materials.     

Cu-Cr粉体致密化颗粒变形及粒子流动三维数值模拟

基于MSC.Marc有限元软件对Cu-Cr粉体颗粒的单、双向致密化过程进行了细观数值模拟分析。研究了不同压制方式及摩檫系数对Cu-Cr粉体颗粒致密度及形貌变化的影响。结果表明:随着摩擦系数的增大,单向压制Cu-Cr粉体颗粒的致密化程度越高,摩擦系数为0.5时,单向压制的Cu-Cr粉体颗粒最高致密度为96.4040%;随着摩擦系数的减小,双向压制Cu-Cr粉体颗粒的致密化程度越高,在无摩擦理想条件下,双向压制Cu-Cr粉体颗粒致密度最高为89.1630%。在相同条件（摩擦系数、压制力）下,单向比双向压制Cu-Cr粉体颗粒有较高的流动性和致密度,Cu颗粒的应变量差值为1.3385,但双向致密化Cu-Cr粉体颗粒比单向压制的粒度均匀性好。模拟结果与实验结果相符合,验证了模型的准确性。      

PIPELINE TRANSPORT OF COARSE PARTICLES BY WATER AND BY FLUIDS WITH YIELD STRESSES

Experiments have been conducted using 1.7 mm and 4 mm particles transported in a pipe 52 mm in diameter. The carrier fluids were water and clay slurries with yield stresses. In several experiments the yield stresses were high enough to support the particles in non-flow situations.

A two layer model was found to be appropriate for interpreting the pressure gradients, with both Coulombic and kinematic friction playing important roles. Kinematic friction appeared to confirm recent experimental results obtained with relatively coarse particles in vertical flows.     

The influence of lateral stresses on brittle–ductile transitions in the die-compaction of sodium chloride

A model has been developed that accounts for the effect of lateral stresses on the deformation of particles occurring during die compaction. This has been examined using the model material sodium chloride. The lateral stresses were found to inhibit cracking of the particles during compaction. Agreement between the theory and experimental results was obtained. This revised version was published online in November 2006 with corrections to the Cover Date.     

Compaction of homogeneous (Mn,Zn)-ferrite potcores

The compaction of thin-walled potcore compacts (height 10 mm, diameter 15 mm, wall thickness 1 mm) with a high homogeneity is analysed. High homogeneity implies that the density is uniform throughout the compact. In order to attain this goal, internal and external friction are minimized while the mode of pressing and pressing velocity are optimized. Internal friction refers to friction between the powder particles, which is influenced by the particle size distribution and additives. The use of five different additives is evaluated. External friction relates to the friction between the powder and the die wall, which is influenced by the relative hardness of the die wall and lubricants. The effects of three different coatings and a lubricant on friction with the die wall have been investigated. The homogeneity of compacts with complicated shapes is affected by the formation of large local density gradients, which lead to differential shrinkage during sintering. By characterizing the shape of sintered products, it is shown that the inhomogeneity in compacts is reduced by optimizing the pressing mode and the pressing velocity. This improves the variation of the diameter over the height of the sintered potcores from 3 to 1.0%     

Evaluation and Correlation of Residual Stress Measurement in Steel

The stress patterns relevant for the assessment of the post production service behaviour of plain carbon hot strip mill plates were evaluated on the surface and at various depths. The hole drilling strain gage (HDSG) is a standard, well proven, semi-destructive technique and is employed for the purpose. However, this technique requires skill and is slow in operation. The magnetic Barkhausen technique (MBE) is non destructive and is still in an experimental stage, but has tremendous potential and has been tried here in steel plant environment. The objective is to establish whether MBE technique could be used as an alternative to HDSG technique. The calibration for MBE results was done under controlled compressive and tensile loading. The stress profiles were determined at six locations along rolling and transverse directions using these two techniques. The rolling stresses using HDSG method were found to be tensile near the surface, increase with depth and saturate at 0.5 to 1 mm depths. The transverse stresses were low tensile or compressive near the surface and saturate to low tensile values at similar depths. The stresses (averaged over a certain depth) by MBE are tensile in rolling direction and compressive in transverse direction. Correlation plots between residual stresses by HDSG method up to different depths and average stress by MBE show that that a good correlation exists at 0.35 mm depth. Beyond this depth, correlation is not good. It is true that for the material of the sheet and the frequency employed, the MBE results are not relevant beyond this depth. Also, the equivalent uniform stress as measured by HDSG method would deviate more and more from the actual stress as we go deeper.     

温压技术中的致密化机制

根据聚合物的流动特性和粉末成形特点 ,试验研究了温压条件下金属粉末的塑性变形 ,理论分析了温压技术中的聚合物膜的成形和致密化机制。结果表明 :在压制初期 ,聚合物良好的流动性和较低的摩擦因数改善了金属粉末的充填行为。在压制末期 ,聚合物在金属表面形成一层微米或亚微米级薄膜。这层薄膜与基体结合牢固 ,将金属粉末与粉末隔离开来 ,促进粉末的塑性变形。     

Synchrotron diffraction measurement of residual stresses in friction stir welded 5383-H321 aluminium butt joints and their modification by fatigue cycling

This paper presents two‐dimensional information on the residual stresses in 8 mm 5383‐H321 aluminium plates joined by double pass (DP) friction stir welding (FSW). It considers the inherent variability in residual stress magnitudes along 0.5 m lengths of weld pass, and their modification under a sequence of applied fatigue loads. This represents one of a planned series of experiments aimed at illuminating the effects of fatigue cycling on residual stress fields. In this particular case, the magnitudes of the bending fatigue loads (R= 0.1) were chosen to correlate with the measured proof strengths of the weld metal (approximately 160 MPa) and the parent plate (approximately 260–270 MPa). In four‐point bend S–N tests at R= 0.1 on 40 mm wide FS welded specimens of this alloy and plate thickness, these peak stress levels correspond to lives of around 10⁵ cycles and 10⁷ cycles, respectively. Results from the work indicate that significant variability exists among welded plates in peak compressive stress magnitudes (a range of perhaps ?50 MPa to ?140 MPa), although peak tensile stresses were relatively low and more consistent (from around 0 to 30 MPa). Fatigue loading accentuates the peak‐to‐valley stress change and causes an overall translation of the stresses to become more positive. Peak tensile stresses increase several‐fold during fatigue cycling.     

Failure modes of liquid nitrocarburized and heat treated tool steel under monotonic loading conditions

The tensile properties and failure mode of heat treated and liquid nitrocarburized tool steels were studied. The tested steels are used as die and tool materials for plastic molds and punching/blanking dies, where wear resistance is required. In addition to intense friction, the main die block and other die components are subjected to tensile and repetitive stresses during operation (tension and fatigue loading). Therefore, hardness, tensile, and fatigue resistance are also critical quality parameters that contribute to material reliability and tool life. However, this study is an initial component of research and does not include fatigue data.     

Ni–Zr–Ti–Si–Sn/Cu metallic glass composites prepared by magnetic compaction

Ni–Zr–Ti–Si–Sn/Cu metallic glass (BMG) composites were fabricated by magnetic compaction of powder mixtures. A considerable plastic deformation took place without apparent failure during the dynamic compaction even at room temperature and at a high strain rate. The BMG particles retained their amorphous phase after the dynamic magnetic compaction at 450 °C. The resulting Ni_52.65Zr_28.71Ti_13.57Si_1.33Sn_3.74/60% Cu composite exhibited a remarkable tensile ductility at room temperature combined with high strength: tensile elongation of 28% and ultimate tensile stress up to 1.1 GPa.     

Effect of consolidation pressure on volumetric composition and stiffness of unidirectional flax fibre composites

Unidirectional flax/polyethylene terephthalate composites are manufactured by filament winding, followed by compression moulding with low and high consolidation pressure, and with variable flax fibre content. The experimental data of volumetric composition and tensile stiffness are analysed with analytical models, and the composite microstructure is assessed by microscopy. The higher consolidation pressure (4.10 vs. 1.67 MPa) leads to composites with a higher maximum attainable fibre volume fraction (0.597 vs. 0.530), which is shown to be well correlated with the compaction behaviour of flax yarn assemblies. A characteristic microstructural feature is observed near the transition stage, the so-called local structural porosity, which is caused by the locally fully compacted fibres. At the transition fibre weight fraction, which determines the best possible combination of high fibre volume fraction and low porosity, the high pressure composites show a higher maximum performance in terms of tensile stiffness (40 vs. 35 GPa). The good agreement with the model calculations (fibre compaction behaviour, and composite volumetric composition and mechanical properties), allows the making of a property diagram showing stiffness of unidirectional flax fibre composites as a function of fibre weight fraction for consolidation pressures in the range 0–10 MPa.     

Sintering of ultra high molecular weight polyethylene

Ultra high molecular weight polyethylene (UHMWPE) is a high performance polymer having low coefficient of friction, good abrasion resistance, good chemical resistance etc. It is used in shipbuilding, textile industries and also in biomedical applications. UHMWPE is processed by powder processing technique because of its high melt viscosity at the processing temperature. Powder processing technique involves compaction of polymeric powder under pressure and sintering of the preforms at temperature above its melting point. In this study, we report our results on compaction and sintering behaviour of two grades of UHMWPE with reference to the powder morphology, sintering temperatures and strength development.     

Mechanical properties of friction welded 6063 aluminum alloy and austenitic stainless steel

Friction welding of dissimilar metal combination of aluminum alloy and austenitic stainless steel was examined to investigate the effect of welding conditions on mechanical properties of the dissimilar metal combination. The welded joints were produced by varying forge pressure (F _g), friction pressure (F _r), and burn-off length (B). The joints were subjected to mechanical testing methods such as the tension, notch Charpy impact tests. The tensile strength and toughness decrease with an increase in friction pressure. The tensile strength decreases with an increase in burn-off length at a low forge pressure while tensile strength increases with an increase in burn-off length at a high forge pressure. The tensile failure of the welded joint occurred in aluminum alloy just away from interface in the thermo-mechanically affected zone indicates good joint strength at the condition of low friction pressure, high forge pressure, and high burn-off length. The maximum tensile strength was observed with low friction pressure and high forge pressure. The tensile strength of dissimilar joint is approximately equal to tensile strength of 6063 aluminum alloys at the condition of low friction pressure, high forge pressure, and high burn-off length. The tensile and impact failure of joints was examined under scanning electron microscope and failure modes were discussed.     

电磁场对高速钢与45钢感应摩擦焊接的影响

利用电磁场对金属材料产生的"场致效应",调节摩擦焊接表面的温度场,以改善异种金属摩擦焊接组织及性能.研究了外加电磁场对W6Mo5Cr4V2高速钢和45钢摩擦焊缝显微组织、合金元素扩散及焊接接头力学性能的影响.结果表明,摩擦加热阶段施加电磁场使45钢近缝区铁素体的数量减少;而在顶锻阶段施加电磁场,使45钢侧铁素体数量有所增多.同时,在顶锻阶段施加电磁场作用时,主要合金元素C、Cr、W的扩散区宽度明显增大.在顶锻阶段采用较短的电磁场施加时间和较低的感应电流强度,可以提高W6Mo5Cr4V2高速钢和45钢摩擦焊接头的抗拉强度.     

Surface Modification of Press Dies Used in a Powder Metallurgical Production Process

Cold compaction in a press die and subsequent sintering of diamond particles, homogeneously distributed in a metallic powder as matrix, is one of the most economic ways for the production of diamond composites, used widely for cutting very hard materials like stone and glass. Owing to the very high hardness of diamonds, the wear of the press die is considerably high and because of a short life time, press tools must be substituted regularly. Recently, through plasma nitriding process and deposition of thin solid films, the wear resistance of the press dies has been significantly increased. This work aims at the investigation of the influence of roughness, friction coefficient, and hardness of the inner surface of various dies, which have been modified in different ways, on the physical properties of the compacted diamond segments. It was evidenced that improving the mechanical and tribological properties of the die surface leads to an increase of the hardness and density of the diamond composites produced.     

Microstructure and mechanical properties of friction stir welded Al/Mg2Si metal matrix cast composite

In this research, friction stir weldability of 15 wt.% Mg₂Si particulate aluminum matrix cast composite and effects of tool rotation speed and number of welding passes on microstructure and mechanical properties of the joints were investigated. Microstructural observations were carried out by employing optical and scanning electron microscopy of the cross sections perpendicular to the tool traverse direction. Mechanical properties including microhardness and tensile strength were evaluated in detail. The results showed fragmentation of Mg₂Si particles and Mg₂Si needles existing in eutectic structure in stir zone. Also, homogeneous distribution of Mg₂Si particles was observed in the stir zone as a result of stirring with high plastic strains. Tension test results indicated that tensile strength of the joint had an optimum at 1120 rpm tool rotation speed and decreased with increasing of the number of welding passes. Hardness of the joint increased due to modification of solidification microstructure of the base composite. This research indicates that friction stir welding is a good candidate for joining of 15 wt.% Mg₂Si aluminum matrix composite castings.     

Particle size induced heterogeneity in compacted powders: Effect of large particles

We investigated the effect of particle size distribution on heterogeneity of compacted powders. We used experiments and discrete particle based simulations to compact powders, test the mechanical strength of the compact, and study the microstructure of the compact. A metallic powder which has a wide particle size distribution was used in the experiments. We found that the compaction profile is not reproducible when particles larger than 1/6 of the die diameter are present in the powder sample. The presence of these large particles generate a highly heterogeneous inter-particle contact and bonding forces. The discrete particle simulations showed that for these heterogeneous compacts the tensile strength exhibits high variability, even for one compact if the diametrical compression force is applied along different axes. Based on these results, it is recommend that the largest particle in a powder compact should not exceed one sixth of the die diameter, which is the same as the recommendation of ASTM International D4767 - 11 for compression test of cohesive soils.     

Compaction of fine powders: from fluidized agglomerates to primary particles

In previous works it has been shown that fine powders (particle size 7 μm m) exhibit two well differentiated behaviors in the compaction regime at low consolidation stresses σ _c . At very low stresses the compaction process is governed by a critical-like dynamics of fractal agglomerates previously formed in the fluid-like regime, undergoing a transition from a random loose packed configuration at the jamming transition to a random close packed state. Then agglomerates are disrupted as further pressure is imposed and there is a cross over to a behavior which is ruled by the initial distribution of local voids within the jammed agglomerates that are filled during compaction. In this work we have extended the range of consolidation stresses up to MPa and we have observed a new transition of behavior at kPa. Our measurements indicate that at this level of consolidation agglomerates are fully disrupted. The compaction process is then determined by the rearrangement of primary particles that have lost memory of their initially agglomerated state in fluidization and behave similarly to noncohesive grains.