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Simulation of Aluminum Powder in Tube Compaction Using Equal Channel Angular Extrusion

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Abstract

Aluminum powder in tube compaction with a 25 mm front plug through equal channel angular extrusion (ECAE) at room temperature was modeled using the finite element analysis package ABAQUS. The Gurson model was used in modeling this process. 2-D simulations in a 90° angle die showed better consolidation of powder near the inner edge of the die than the outer edge after one pass of ECAE but almost full densification occurs after two passes. The effect of hydrostatic pressure on densification of the powder was investigated by using two plugs varying in length dimension. The results obtained from the simulations were also compared with experiments conducted to compact aluminum powder with mean particle diameter of 45 μm. Optical microscopy, microhardness test, and density measurements confirmed the simulations. The simulations were extended to powder compaction in a 60° and 120° angle die. It was found that one pass of ECAE is sufficient to consolidate the aluminum powder completely and uniformly in a 60° angle die, whereas the material is still porous in a 120° angle die.

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Authors and Affiliations

  1. Department of Materials Science and Engineering, School of Engineering, Shiraz University, Shiraz, Iran

    Reza Derakhshandeh Haghighi & Ahmad Jenabali Jahromi

  2. Department of Mechanical Engineering, Politecnico di Milano University, Milan, Italy

    Behnam Esfandiar Jahromi

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  1. Reza Derakhshandeh Haghighi
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  2. Ahmad Jenabali Jahromi
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Correspondence to Ahmad Jenabali Jahromi.

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Haghighi, R.D., Jahromi, A.J. & Jahromi, B.E. Simulation of Aluminum Powder in Tube Compaction Using Equal Channel Angular Extrusion. J. of Materi Eng and Perform 21, 143–152 (2012). https://doi.org/10.1007/s11665-011-9896-1

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