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Study on the densification behavior of aluminum powders using microwave hot pressing process

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Abstract

In this study, a method called microwave-assisted hot compaction process was used to fabricate bulk Al sample. After the cold pressing process of Al powders, the green compact was hot-pressed in a microwave-assisted hot press apparatus at 400 °C under the pressure of 50 MPa. Moreover, numerical simulation of microwave-assisted hot compaction process was performed using 3D finite element method. Comparison between numerical and experimental results was also investigated. The microstructure, pore distribution, and surface topography of the sample were observed by scanning electron and atomic force microscopes. The density of the bulk sample was measured by Archimedes technique. Finally, nanoindentation test was carried out to measure hardness and elastic modulus. The results showed that the sample was heated uniformly using microwave heating process. Despite the uniform heating, the top corner regions of sample exhibited higher density as compared to the bottom corner regions. However, the central regions of the sample consolidate uniformly. Also, the top corners of the sample with more densification showed an improvement in the mechanical properties of the sample.

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Correspondence to Reza Abedinzadeh.

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Highlights

• Bulk Al sample was produced by the microwave hot pressing process.

• Numerical simulation of microwave hot pressing process was performed using finite element method.

• The high heating rate and pressure were used simultaneously during compaction process to achieve more densification.

• Energy consumption was reduced by decreasing the sintering temperature and holding time to produce the Al sample.

• An increase in the amount of porosity resulted in decrease the hardness and elastic modulus of the Al sample.

• The comparative study was carried out between different sintering methods to consolidate the Al sample.

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Abedinzadeh, R. Study on the densification behavior of aluminum powders using microwave hot pressing process. Int J Adv Manuf Technol 97, 1913–1929 (2018). https://doi.org/10.1007/s00170-018-1867-3

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  • DOI: https://doi.org/10.1007/s00170-018-1867-3

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