INVESTIGATION ON THE DENSITY UNIFORMITY OF PRESSED PARTS BY LOW-VOLTAGE ELECTROMAGNETIC COMPACTION

1.IntroductionElectromagnetic compaction is a kind of high-energy and high-speed forming method. Magnetic forces have been used for more than two decades in powder compaction[1,2]. Powder Electromagnetic compaction refers to a new efficient forming technology, which uses the strong pulse electromagnetic power to compact powder to pressed density. The corresponding principle is as follows: by dint of magnetism pulse equipments, capacitor groups discharge electricity to generate the pulse m…     

粉末低电压电磁压制实验研究

将低电压电磁成形方法用于粉末材料压制 ,采用间接加工方式对铝、铜、锡粉进行了压制实验 ,在成功压制出高密度粉末制品的基础上 ,分析了电压、电容、摩擦、压制次数、粉末粒度等因素对制品压实密度的影响。实验结果表明 ,对不同粉末材料 ,在保证一定加载速率和放电能量的前提下 ,降低电压和增加电容 ,有利于提高粉末制品压实密度及其均匀性 ;电压越高 ,摩擦能量消耗率越大 ;当设备放电能量有限时 ,多次压制是获得致密均匀、高密度粉末制品的有效途径     

Dynamic Compaction of Pure Copper Powder Using Pulsed Magnetic Force

The compaction of pure Cu powder was carried out through a series of experiments using dynamic magnetic pulse compaction, and the effects of process parameters, such as discharge energy and compacting direction, on the homogeneity and the compaction density of compacted specimens were presented and discussed. The results indicated that the compaction density of specimens increased with the augment of discharge voltage and time. During unidirectional compaction, there was a density gradient along the loading direction in the compacted specimen, and the minimum compaction density was localized to the center of the bottom of the specimen. The larger the aspect ratio of a powder body, the higher the compaction density of the compacted specimen. And high conductivity drivers were beneficial to the increase of the compaction density. The iterative and the double direction compaction were efficient means to manufacture the homogeneous and high-density powder parts.     

Effects of processing parameters on density and electric properties of electric ceramic compacted by low-voltage electromagnetic compaction

In this research, low-voltage electromagnetic compaction (EMC) was applied to compact TiO₂ and PZT powders in the indirect way. After selecting the appropriate processing parameters, TiO₂ and PZT ceramics of higher density and better electrical properties were produced compared with traditional static compaction. The microstructures of two ceramics produced by two above-mentioned methods respectively show that, the average grain size of TiO₂ and PZT compacted by low-voltage EMC are about 8 μm and 4 μm which are smaller than that by static compaction respectively (15 μm and 7 μm) under the same sintered condition. Discharge voltage and charge capacitance are important factors to the green density and sintered part's density of each ceramics. Meanwhile, TiO₂ and PZT have their own discharge voltage range (700–1100 V for TiO₂ and 600–1000 V for PZT), during which each ceramic powder could be pressed effectively. With the same condition of charge capacitance, as the discharge voltage increases toward a peak value, the green density and sintered part's density increase, then tend to decrease after that peak value. The green density and sintered part's density of each ceramic increase and the above peak discharge voltage decrease slightly, as charge capacitance enlarges in the range investigated. In addition, effects of pancake coil turns and field shaper structure on the ceramic density were investigated. In most of cases investigated, the higher the ceramic part's density, the better the dielectric constants of TiO₂ parts and the piezoelectric constants of PZT parts.     

PZT陶瓷粉末低电压电磁压制实验研究

以PZT陶瓷粉末为研究对象,采用间接加工方式对其进行低电压电磁压制成形,在成功压制出高密度制品的基础上,分析了电压、电容、毛坯尺寸、压制次数等参数对压实密度的影响。研究结果表明,PZT陶瓷粉末低电压电磁压制存在一个可成形的放电电压范围,在此范围内,压制密度先随电压增加而增加,烧结性能也不断得到改善,最终使得烧结后陶瓷制品密度提高;但电压越高,制品密度增幅趋缓,至最佳放电电压后,压制密度开始下降,而制品密度则急剧下降;同样,增加电容也能一定程度地提高PZT陶瓷粉末压实密度并改善其烧结性能,降低最佳放电电压;其他放电参数不变的条件下,制品高径比越大,压实密度越低,且最佳放电电压提高,烧结后制品密度降低;两次压制可以有效提高压制密度,降低最佳放电电压,改善陶瓷坯体的烧结性能,并最终提高功能陶瓷制品致密度,在设备能量不足的情况下,两次压制是一种获得高致密PZT陶瓷制品的有效方法;相比静力压制,低电压电磁压制能提高PZT陶瓷坯体密度,并改善陶瓷体的烧结性能。     

Investigations in the compaction and sintering of large ceramic parts

In this study, a large ceramic part was successfully compacted and sintered using uniaxial die compaction technique. The effects of die design, compaction pressure, lubrication, sintering procedure and part orientation in the oven on the P/M part quality were investigated and the preferred process conditions were discussed and concluded. The main quality issues encountered were cracking and distortion. A finite element model for the powder compaction process was also developed and validated. Based on the model, the relationship between the cracking location and the density distribution predicted from finite element analysis (FEA) was discussed.     

Analysis of density and mechanical properties of high velocity compacted iron powder

A new method for producing higher density PM parts, high velocity compaction (HVC), was presented in the paper. Using water atomized pure iron powder without lubricant admixed as the staring material, ring samples were compacted by the technique. Scanning electron microscopy (SEM) and a computer controlled universal testing machine were used to investigate the morphologies and the mechanical properties of samples, respectively. The relationships among the impact velocity, the green density, the sintered density, the bending strength and the tensile strength were discussed. The results show that with increasing impact velocity, the green density and the bending strength increase gradually, so the sintered density does. In addition, the tensile strength of sintered material is improved continuously with the sintered density enhancing. In the study, the sintered density of 7.545~g/cm³ and the tensile strength of 190~MPa are achieved at the optimal impact velocity of 9.8 m/s.     

C／CuPb复合轴承材料温压成形工艺的研究

用温压工艺制得了短碳纤维增强铜铅合金（Ｃ／ＣｕＰｂ）复合轴承材料,研究了温压工艺参数对温压压坯及烧结坯性能的影响,并对温压烧结与冷压烧结及二次压制烧结所得Ｃ／ＣｕＰｂ复合轴承材料的性能进行了分析对比。结果表明,温压压坯比冷压压坯具有更高的生坯密度,同时,温压烧结Ｃ／ＣｕＰｂ复合轴承材料的性能与二次压制烧结材料相当而明显高于冷压烧结材料。     

Investigations on heat regulation of additive manufacturing processes for metal structures

By using additive manufacturing processes various powder materials can be melted and geometrically complex parts can be built. There is a need for high energy density to melt a metal powder layer locally. Therefore a laser beam is used to induce the required temperature level. To attain a more homogeneous temperature distribution a heating unit is integrated. To identify the thermal influences a model has been developed and validated by using tungsten carbide. To evaluate the achieved results different quality criteria have been determined. However, both process stability and part quality can be increased by minimizing temperature gradient mechanisms.     

Stresses State and Mechanical Behaviors of the Green Body During Die Compaction and Ejection Process

Finite element simulations for metal powder compaction of a clutch plate were performed to examine the stresses during compaction, unloading, and ejection. To describe the mechanical behavior of compacted green body, a modified density-dependent Drucker-Prager Cap model was utilized to predict the stress and density distribution of the compacted clutch plate during loading and ejection stages. The results indicate that maximum tensile principal stress was a main driving force for the tensile crack initiation during ejection stage, and shear stress may be another driving force in both compaction and ejection stages for shear crack initiation. There were peak value of the stresses during ejection stage, and the stresses are in compressive state only during compaction stage. Therefore, the tensile crack initiation is not possible during compaction except shear crack. Hoop stress in the clutch plate is of less contribution to the crack initiation during compaction, unloading and ejection. Study of criteria of the crack initiation and fracture is necessary in order to obtain uniform density and crack-free components in the manufacturing of metal powder compaction.     

装粉方式对钛粉压制成形影响的数值模拟

用MSC.Marc软件模拟了3种不同装粉方式下钛粉压制成形过程中粉末的流动情况及压坯的密度分布规律.结果表明:粉末装粉方式对粉末压制过程及压坯密度有较大的影响,与平式装粉方式相比,采用凸式装粉,试样的烧结坯密度提高了6%,孔隙分布的均匀性也得到相应的改善.     

铜粉螺线管线圈磁脉冲致密试验研究

将电磁成形技术用于粉末材料致密，利用螺线管线圈对铜粉进行了致密试验。分析了放电电压、致密次数、加热温度等因素对压坯致密度的影响。试验结果表明增加放电电压、多次放电、对粉末进行预热，均能提高压坯的平均致密度。在压坯轴向上距离中心越远的位置致密度越低，在径向上距离中心越远的位置致密度越高。     

RESEARCH AND SIMULATION OF THE INFLUENCE OF THREE-AXIAL COMPACTION ON POWDER METALLURGIC PRODUCT PROPERTIES

The warm powder compaction process is simulated by the finite element analysis software, MSC/MARC. The thermal mechanically coupled analysis method is applied on the basis of the updated Lagrangian Method, to simulate the warm powder compaction process. The warm powder compaction process is simulated, and the influence of friction condition and pressing styles are researched on the density of powder green and the mechanics behavior at certain temperature. The results indicate that for cylindrical compacts, with the improvement of the friction condition, the uniformity of distribution of green relative density is largely improved, the pressing force and stress decrease, and the nonconforming pressing processes influence the distribution of green density to some degree. The status of stress distribution of the process that punches firstly press and die finally press is different from the other three processes, and presents the figure of 'flume'.     

Research and Simulation of Influence of Three-Axial Compaction on Powder Metallurgic Products Properties

The warm powder compaction process is simulated by the finite element analysis software, MSCJMARC. The thermal mechanically coupled analysis method is applied on the basis of the updated Lagrangian Method, to simulate the warm powder compaction process. The warm powder compaction process is simulated, and the influence of friction condition and pressing styles are researched on the density of powder green and the mechanics behavior at certain temperature. The results indicate that for cylindrical compacts, with the improvement of the friction condition, the uniformity of distribution of green relative density is largely improved, the pressing force and stress decrease, and the nonconforming pressing processes influence the distribution of green density to some degree. The status of stress distribution of the process that punches firstly press and die finally press is different from the other three processes, and presents the figure of ＇flume ＇.     

Functionalisation of PM components by integration of inherent data carriers and sensory elements

Apart from a great variety of shaping possibilities powder metallurgical techniques offer integration of foreign elements for permanent and variable data storage or embedding of elements with sensory features in structural parts. By integrating foreign elements as single parts arranged in matrices or traces of foreign powders information like brand, serial numbers or other codable data can be stored in a part. Integrated sensor elements can be used to monitor loading conditions like strains and stresses or temperatures during the life-cycle of technical parts. In this research work foreign elements are embedded in the powder prior to compaction. The powder is compacted to a green body and sintered afterwards. During compaction the foreign elements interact with the base material and change their position according to the deformation of the surrounding powder. Finite element analyses are carried out in order to detect a suitable initial arrangement of foreign elements and to ensure their correct position at the end of the compaction. Furthermore, the interface conditions between the base powder and the foreign elements are of interest. Therefore, experimental investigations are carried out with magneto-elastic sensors consisting of NiFe-layers on different substrates such as aluminum, Silicon and aluminum oxide with aluminum and Steel powder. The bonding quality is analyzed by metallographic investigations. By means of X-ray and computed tomography (CT) the position of the foreign elements within the parts is controlled, which is vital for a correct determination of loading conditions and for the read-out of stored information.     

Microstructure and mechanical properties of Ti6Al4V powder compacts prepared by magnetic pulse compaction

Ti6Al4V powder compaction was performed by using magnetic pulse compaction in air at 200℃.Effects of process parameters such as voltage,capacitance,discharge times on the microstructure,compressive strength,hardness and relative density of compacts were investigated.The experimental results show that the relative density,hardness and compressive strength of compacted specimens increase with increasing voltage.In addition,the relative density and compressive strength of compacted specimens increase with the augmentation of capacitance in the range investigated.The relative density increases,the hardness firstly increases and then tends to be a fixed value;and the compressive strength firstly increases and then decreases from one to five times compaction.Both values of the hardness and compressive strength reach the maxima of HRA 69.1 and 1 062.31 MPa,at three times compaction,respectively.There are pores in and between particles.     

Warm compaction powder metallurgy of Cu

A series of experiments were carried out using different admixed lubricant contents, different compaction pressures and temperatures in order to study the warm compaction of copper powder. Results show that too much admixed lubricant will lead to the squeeze out of the lubricant from the compact during the warm compaction processing of Cu powder. Results also show that blisters can be found in sintered samples that contain lubricant less than 0.15%(mass fraction). Optimal warm compaction parameters for producing high density powder metallurgy copper material are obtained. Compacts with green density of 8.6 g/cm^3 and a sintered density of 8.83 g/cm3 can be produced by warm compacting the Cu powder, which contains 0.2% admixed lubricant, and is compacted at 145℃ with a pressure of 700 MPa.     

Warm die compaction and sintering of titanium and titanium alloy powders

A study has been made of the effect of non-lubricated warm die (200 °C) compaction on the densification of hydride–dehydride (HDH) Ti powder, pre-alloyed (PA) Ti-6Al-4V and Ti-10V-2Fe-3Al powders, and HDH Ti and V-Fe-Al master alloy powder blends, compared to cold die compaction. Depending on the compaction pressure, which was varied from 200 to 1000 MPa, non-lubricated warm die (200 °C) compaction was very effective for −100 mesh HDH Ti powder, increasing the green density by 5.0–9.4% theoretical density (TD). Die wall lubrication with stearic acid showed no influence on the green density when compacted at 800 MPa. With warm die (200 °C) compaction, achieving a green density of greater than 90%TD was straightforward for HDH Ti powder when compacted at ≥750 MPa. Accordingly, near pore-free (≥99.5%TD) Ti microstructures were obtained after sintering at 1300 °C for 120 min in vacuum when compacted at 1000 MPa. The resulting increment in the sintered density was between 2.0%TD and 4.4%TD. Warm die (200 °C) compaction showed no effect on PA Ti-10V-2Fe-3Al powder and only a small effect on PA Ti-6Al-4V powder when compacted at 1000 MPa. However, it was still virtually effective for Ti-10V-2Fe-3Al powder blends made of HDH Ti powder and V-Fe-Al master alloy powder. The observations were compared with literature data and discussed in accordance with the yield strength of Ti, Ti-6Al-4V, Ti-10V-2Fe-3Al and Al₃V as a function of temperature.     

现代粉末冶金材料和技术发展现状(一)

概述现代粉末冶金材料和技术的发展现状。介绍了传统粉末冶金材料与先进粉末冶金材料的基本特性、应用情况及发展趋势,较系统介绍了机械合金化、粉末注射成形、温压成形、喷射成形、微波烧结、放电等离子烧结、自蔓延高温合成、烧结硬化等新技术的研究与开发状况。内容分（一）、（二）两部分,分两期发表。     

现代粉末冶金材料和技术发展现状(二)

概述现代粉末冶金材料和技术的发展现状。介绍了传统粉末冶金材料与先进粉末冶金材料的基本特性、应用情况及发展趋势,较系统介绍了机械合金化、粉末注射成形、温压成形、喷射成形、微波烧结、放电等离子烧结、自蔓延高温合成、烧结硬化等新技术的研究与开发状况。内容分一、二两部分,分两期发表。