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.
Similar content being viewed by others
References
Jang B-K, Matsubara H (2005) Influence of porosity on hardness and Young's modulus of nanoporous EB-PVD TBCs by nanoindentation. Mater Lett 59(27):3462–3466
German RM (2005) Powder metallurgy and particulate materials processing: the processes, materials, products, properties, and applications. Metal Powder Industries Federation, Princeton
Fulay P, Askeland D (2009) Essentials of materials science and engineering. Cengage Learning, Toronto
Burke J (2012) Ultrafine-grain ceramics, vol 15. Springer Science & Business Media, New York
Kapylou AV, Urbanovich VS, Andrievski RA, Kuznetsov DA, Nohrin AV, Klimczyk P (2009) Effect of compacting pressure, powder degassing and thermobaric treatment on densification and properties of nanocrystalline titanium nitride. Process Appl Ceramics 3(3):161–166
Martínez C, Briones F, Rojas P, Ordoñez S, Aguilar C, Guzmán D (2017) Microstructure and mechanical properties of copper, nickel and ternary alloys Cu-Ni-Zr obtained by mechanical alloying and hot pressing. MRS Adv 2(50):2831–2836
Essa K, Khan R, Hassanin H, Attallah MM, Reed R (2016) An iterative approach of hot isostatic pressing tooling design for net-shape IN718 superalloy parts. Int J Adv Manuf Technol 83(9–12):1835–1845
Argüello JG, Fossum AF, Zeuch D, Ewsuk KG (2001) Continuum-based FEM modeling of alumina powder compaction. KONA Powder Part J 19:166–177
Abdelhafeez A, Essa K (2016) Influences of powder compaction constitutive models on the finite element simulation of hot isostatic pressing. Procedia CIRP 55:188–193
Parteder E, Riedel H, Sun D-Z (2002) Simulation of hot forming processes of refractory metals using porous metal plasticity models. Int J Refract Met Hard Mater 20(4):287–293
Haghighi RD, Jahromi AJ, Jahromi BE (2012) Simulation of aluminum powder in tube compaction using equal channel angular extrusion. J Mater Eng Perform 21(2):143–152
Wei Q, Xue P, Liu G, Lu H, Huang J, Shi Y (2014) Simulation and verification of near-net shaping a complex-shaped turbine disc by hot isostatic pressing process. Int J Adv Manuf Technol 74(9–12):1667–1677
Mudinepalli VR, Leng F, Lin W, Murty B (2016) Conventional and spark plasma sintered Ba0.8Pb0.2TiO3 nano ceramics: structural, dielectric, and ferroelectric properties. Metall Mater Trans A 47(6):2579–2586
Zhu H, Liang S, Ouyang T, Yue S, Jiang J (2017) Thermoelectric properties of CoSb3 and CoSb3/SiC composites prepared by mechanical alloying and microwave sintering. J Mater Sci Mater Electron 28(14):10509–10515
Oghbaei M, Mirzaee O (2010) Microwave versus conventional sintering: a review of fundamentals, advantages and applications. J Alloys Compd 494(1):175–189
Kang J-K, Dinh TH, Lee C-H, Han H-S, Lee J-S, Tran VDN (2017) Comparative study of conventional and microwave sintering of large strain bi-based perovskite ceramics. Trans Electr Electron Mater 18(1):1–6
Zhao X, Yan L, Huang K (2011) Review of numerical simulation of microwave heating process. In: Advances in induction and microwave heating of mineral and organic materials. InTech
Mishra P, Upadhyaya A, Sethi G (2006) Modeling of microwave heating of particulate metals. Metall Mater Trans B 37(5):839–845
Mondal A, Shukla A, Upadhyaya A, Agrawal D (2010) Effect of porosity and particle size on microwave heating of copper. Sci Sinter 42(2):169–182
L-y H, Y-c S, Liu Y, Gao L, Wang Q-t, X-n Z (2016) The study of microwave and electric hybrid sintering process of AZO target. Adv Mater Sci Eng. https://doi.org/10.1155/2016/5294062
Varghese J, Joseph T, Surendran K, Rajan T, Sebastian M (2015) Hafnium silicate: a new microwave dielectric ceramic with low thermal expansivity. Dalton Trans 44(11):5146–5152
Oliver WC, Pharr GM (1992) An improved technique for determining hardness and elastic modulus using load and displacement sensing indentation experiments. J Mater Res 7(06):1564–1583
Thostenson E, Chou T-W (1999) Microwave processing: fundamentals and applications. Compos A: Appl Sci Manuf 30(9):1055–1071
Incropera FP, Lavine AS, Bergman TL, DeWitt DP (2007) Fundamentals of heat and mass transfer. Wiley, New York
Tvergaard V (1981) Influence of voids on shear band instabilities under plane strain conditions. Int J Fract 17(4):389–407
Tvergaard V (1982) On localization in ductile materials containing spherical voids. Int J Fract 18(4):237–252
Kushch V, Podoba YO, Shtern M (2008) Effect of micro-structure on yield strength of porous solid: a comparative study of two simple cell models. Comput Mater Sci 42(1):113–121
Bier W (2008) A constitutive model for metal powder and its numerical treatment using finite elements. Kassel University Press GmbH, Kassel
Fritzen F, Forest S, Böhlke T, Kondo D, Kanit T (2012) Computational homogenization of elasto-plastic porous metals. Int J Plast 29:102–119
Elzey D, Wadley H (1993) Modeling the densification of metal matrix composite monotape. Acta Metall Mater 41(8):2297–2316
Olsson E, Larsson P-L (2013) A numerical analysis of cold powder compaction based on micromechanical experiments. Powder Technol 243:71–78
Tvergaard V (1989) Material failure by void growth to coalescence. Adv Appl Mech 27:83–151
Cunningham B (2017) Simulating powder compaction with porous plasticitymodels. Comsol Blog. http://www.comsol.com/blogs/simulating-powder-compaction-with-porous-plasticity-models Accessed 20 November 2017
Eisen W, Ferguson B, German R, Iacocca R, Lee P, Madan D, Moyer K, Sanderow H, Trudel Y (1998) Powder metal technologies and applications. ASM International, Ohio
Faghri A, Zhang Y (2006) Transport phenomena in multiphase systems. Elsevier Academic Press, London
Faghri A, Zhang Y, Howell JR (2010) Advanced heat and mass transfer. Global Digital Press, Columbia
Chinh NQ, Illy J, Horita Z, Langdon TG (2005) Using the stress–strain relationships to propose regions of low and high temperature plastic deformation in aluminum. Mater Sci Eng A 410:234–238
Mahoney FM, Readey M (1995) Applied mechanics modeling of granulated ceramic powder compaction. Sandia National Labs, Albuquerque
Kim K, Choi S, Park H (2000) Densification behavior of ceramic powder under cold compaction. Trans Am Soc Mech Eng J Eng Mater Technol 122(2):238–244
Kadhim KMJ, Alwan AA, Abed IJ (2011) Simulation of cold die compaction alumina powder. Trends Mech Eng Technol 1(1):1–21
Carlone P, Palazzo G (2007) Cold compaction of ceramic powder: computational analysis of the effect of pressing method and die shape. Int Appl Mech 43(10):1174–1178
Selig SG, Doman DA (2015) Finite element simulation of the compaction and springback of Alumix 321 PM alloy. J Appl Math 2015:1–7
Lee S, Kim K (2002) Densification behavior of aluminum alloy powder under cold compaction. Int J Mech Sci 44(7):1295–1308
Wu C-Y, Ruddy O, Bentham A, Hancock B, Best S, Elliott J (2005) Modelling the mechanical behaviour of pharmaceutical powders during compaction. Powder Technol 152(1):107–117
Zhou M, Huang S, Hu J, Lei Y, Xiao Y, Li B, Yan S, Zou F (2017) A density-dependent modified Drucker-Prager Cap model for die compaction of Ag57. 6-Cu22. 4-Sn10-In10 mixed metal powders. Powder Technol 305:183–196
Wu C, Elliott J, Bentham A, Best S, Hancock B, Bonfield W (2004) A numerical study on the mechanical behaviour of pharmaceutical powders. In: Proc. Int. conf. on Pharmaceutics, Biopharmaceutics and Pharmaceutical Technology, 15th–18th March, Nuremberg, Germany, pp 17–18
German R (2014) Sintering: from empirical observations to scientific principles. Butterworth-Heinemann, Waltham
German RM (1984) Powder metallurgy science. Metal Powder Industries Federation, Princeton
Heckel R (1961) Density-pressure relationships in powder compaction. Trans Metall Soc AIME 221(4):671–675
Sultan N, Delage P, Cui Y (2002) Temperature effects on the volume change behaviour of Boom clay. Eng Geol 64(2):135–145
Pieczonka T, Schubert T, Baunack S, Kieback B (2008) Dimensional behaviour of aluminium sintered in different atmospheres. Mater Sci Eng A 478(1):251–256
Flumerfelt JF (1998) Aluminum powder metallurgy processing. Digital Repository@ Iowa State University. http://lib.dr.iastate.edu/, Ames, Iowa
Padmavathi C, Upadhyaya A, Agrawal D (2012) Microwave assisted sintering of Al-Cu-Mg-Si-Sn alloy. J Microw Power Electromagn Energy 46(3):115–127
Reddy MP, Ubaid F, Shakoor R, Mohamed A, Madhuri W (2016) Structural and mechanical properties of microwave sintered Al Ni 50 Ti 50 composites. J Sci Adv Mater Devices 1(3):362–366
Chu MY, Rahaman MN, Jonghe LC, Brook RJ (1991) Effect of heating rate on sintering and coarsening. J Am Ceram Soc 74(6):1217–1225
Saheb N (2013) Spark plasma and microwave sintering of Al6061 and Al2124 alloys. Int J Miner Metall Mater 20(2):152–159
McKimpson MG (1996) Densification maps for nano-sized powders. Mater Manuf Process 11(6):935–949
Sinha A, Farhat Z (2014) A study of porosity effect on tribological behavior of cast Al A380M and sintered Al 6061 alloys. J Surf Eng Mater Adv Technol 5(01):1
Kováčik J (2001) Correlation between shear modulus and porosity in porous materials. J Mater Sci Lett 20(21):1953–1955
Wang JC (1984) Young’s modulus of porous materials. J Mater Sci 19(3):801–808
Wellman R, Dyer A, Nicholls J (2004) Nano and micro indentation studies of bulk zirconia and EB PVD TBCs. Surf Coat Technol 176(2):253–260
Chen X, Xiang Y, Vlassak JJ (2006) Novel technique for measuring the mechanical properties of porous materials by nanoindentation. J Mater Res 21(3):715–724
Ling Z, Wang X, Ma J (2008) The response of porous Al2O3 probed to nanoindentation. Mater Sci Eng A 483:285–288
Karaoglanli A, Turk A, Ozdemir I (2016) Effect of sintering on mechanical properties of cold sprayed thermal barrier coatings. Surf Eng 32(9):686–690
Sinha A, Farhat Z (2015) Effect of surface porosity on tribological properties of sintered pure Al and Al 6061. Mater Sci Appl 6(06):549
Ewais OH, Al Abbassy F, Ghoneim MM, Aboushelib MN (2014) Novel zirconia surface treatments for enhanced osseointegration: laboratory characterization. Int J Dent 2014:1–8
He Y, Winnubst L, Burggraaf AJ, Verweij H, Varst PGT, With B (1997) Influence of porosity on friction and wear of tetragonal zirconia polycrystal. J Am Ceram Soc 80(2):377–380
Author information
Authors and Affiliations
Corresponding author
Additional information
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.
Rights and permissions
About this article
Cite this article
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
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-1867-3