Sharif Digital Repository

In the present work, co-sintering of various powder injection molding (PIM) feedstocks including iron, low-alloy steels, high-alloy steels, and hardmetals was investigated. Dilatometric analysis was used to evaluate the sintering behaviour of co-injection moulded feedstocks after debinding. An approach based on the data of dimensional change versus time and temperature was proposed to determine the compatibility of two materials system for the two component powder injection molding (2C-PIM) process. The similarity of sintering behaviour of the twobody parts produced by 2C-PIM was quantified trough definition of a parameter termed as Apparent Co-Sintering Index (ACSI). The results determined... 

Solid-state joining of powder-metallurgy processed (P/M) Al–2 vol% Al2O3 (15 nm) nanocomposite by friction stir welding (FSW) was studied. The nanocomposite was prepared via high-energy mechanical milling followed by hot consolidation processes. The microstructure, mechanical properties and fracture behavior of the welds were evaluated and compared with FSWed wrought 1050 aluminum sheets (WAS). We have found that unlike WAS that can processed at various FSW conditions, the working window for the solid-state joining of P/M nanocomposite is narrow and only feasible at relatively high heating inputs. Microstructural studies showed the formation of melted zones with high hardness at the... 

In this paper, the coupled thermo–mechanical simulation of hot isostatic pressing (HIPing) is presented for metal powders during densification process. The densification of powder is assumed to occur due to plastic hardening of metal particles. The constitutive model developed is used to describe the nonlinear behavior of metal powder. The numerical modeling of hot powder compaction simulation is performed based on the large deformation formulation, powder plasticity behavior, and frictional contact algorithm. A Lagrangian finite element formulation is employed for the large powder deformations. A modified cap plasticity model considering temperature effects is used in numerical simulation... 

A zirconia/alumina nanocomposite stabilized with cerium oxide (Ce-TZP/Al2O3 nanocomposite) can be a good substitute as reinforcement in metal matrix composites. In the present study, the effect of the amount of 10Ce-TZP/Al2O3 particles on the microstructure and properties of Al/(10Ce-TZP/Al2O3) nanocomposites was investigated. For this purpose, aluminum powders with average size of 30μm were ball-milled with 10Ce-TZP/Al2O3 nanocomposite powders (synthesized by aqueous combustion) in varying amounts of 1, 3, 5, 7, and 10wt.%. Cylindrical-shape samples were prepared by pressing the powders at 600MPa for 60min while heating at 400-450°C. The specimens were then characterized by scanning and... 

In this study hydroxyapatite (HA)/zirconia/alumina composite coatings on titanium metal was carried out using Sol-Gel dip coating and calcination process. Hydroxyapatite-Alumina-Zirconia sol, coated samples in three processes by changing final sol stirring time, aging time, calcination temperature of synthesized powder and prepared coating and rate of coating. Some parts of prepared sol were also synthesized and became powder in all three processes. Scanning electron microscopy was used to estimate the particle size of the surface and for morphological analysis. The functional group and crystallization characteristics of the powders were analyzed using (FTIR) and X-Ray diffraction (XRD).... 

FeNiCo base powder alloy with nominal composition Fe-27Ni-17Co-4Ti (wt%) was prepared from elemental powders by mechanical alloying. The structure of milled powders was characterized by XRD and SEM. The effect of nanosize structure on magnetic properties and shape memory behavior was studied using VSM and DSC. After milling for 240 minutes by high energy vibrational ball mill under argon atmosphere, supersaturated solid solution formed with mean crystallite size of ∼20 nm. Results of VSM examinations showed that by milling for 240 minutes saturation magnetization and intrinsic coercivity reached 304 emu/gr and 21 Oe, respectively. XRD analyses made it clear that transformation from BCC to... 

The thermal decomposition of Aluminum Titanate in exposure to pure Aluminum was examined both in powder and in bulk form. Optical microscopy, FE-SEM, XRD, DSC and TGA examinations were conducted to take the possible chemical reactions between Aluminum Titanate and Al into consideration. It was found that as Aluminum Titanate particles are exposed to Al matrix, the thermal stability of Aluminum Titanate is degraded and its decomposition temperature is reduced from 850°C to 550°C. Also, the chemical reactions between Aluminum Titanate and Al start along the interfaces, and the reaction products, i.e. Al3Ti, Al2O3, TiO2 and O2 gas are left there. A mechanism was suggested to describe the... 

In this paper, an optimal design is performed for powder die-pressing process based on the genetic algorithm approach. It includes the shape optimization of powder component, the optimal design of punch movements, and the friction optimization of powdertool interface. The genetic algorithm is employed to perform an optimal design based on a fixed-length vector of design variables. The technique is used to obtain the desired optimal compacted component by verifying the prescribed constraints. The numerical modeling of powder compaction simulation is applied based on a large deformation formulation, powder plasticity behavior, and frictional contact algorithm. A Lagrangian finite element... 

Copper matrix composites reinforced with TiO2particles are promising materials widely used as contact materials due to their excellent mechanical and physical properties such as good electrical and thermal conductivity and strength at high temperature. In this research, the novel contact material were prepared by in-situ oxidation of Cu-Ti pre alloyed powders. The morphology of milled powders and microstructure of nano-composite specimens were studied by SEM and TEM. To evaluate mechanical alloying progress of Cu and Ti powders mixture and internal oxidation after Cu2O addition, XRD analysis were carried out. The Physical and mechanical properties results of specimens indicate that the... 

High-energy milling technique was used to synthesize Al-10 wt.%AlN-nanostructured composite powder in a planetary ball-mill under argon atmosphere up to 25 h. To show the role of AlN particles, process was conducted for monolithic aluminum. The changes in powder characteristics were investigated by time. Microstructure of powders was studied after different milling times by scanning electron microscope (SEM). The morphological evolutions showed that relative equiaxed powder could be synthesized after 25 h milling. Structural analysis was performed by X-ray diffraction method (XRD) to determine the grain sizes and lattice strain. Furthermore, particle size analysis (PSA) revealed the... 

Laser sintering of Fe-C-Cu steel powder for rapid manufacturing of sintered components for functional testing was studied. The effects of C and Cu addition on the densification and the attendant microstructural features were investigated. The influence of iron particle size on the sintering kinetics was also examined. It is shown that the alloying elements significantly improve the densification rate when fine iron particles and high laser intensity are used. The mechanism of particle bonding and the effect of the alloying elements are presented. © 2008 Elsevier B.V. All rights reserved  

To study the effect of the production method on physical and mechanical properties of Cu-rGO nanocomposites, nanocomposite powder samples with rGO content of 0.25–1 wt.% were prepared via combined routes of molecular-level mixing (MLM) and powder metallurgy (PM). Spark plasma sintering (SPS) was applied to consolidate nanocomposite powders with better control on the grain size. According to the specific electrical resistivity measurements, microhardness, and pin-on-disk wear tests, the sample with 0.5 wt.% rGO comprised the best overall properties. For assessment, samples containing 0.5 wt.% rGO were also produced via PM and MLM routes, separately. The physical and mechanical properties of... 

The compaction forming of metal powder is a process involving large deformations, large strain, non-linear material behavior and friction. Consequently, the numerical analysis of such a highly non-linear process is a formidable computational problem. In this paper, an ALE technique is presented based on a generalized cap plasticity model in simulation of powder forming processes. In ALE formulation, the reference configuration is used for describing the motion, instead of material configuration in Lagrangian, and spatial configuration in Eulerian formulation. This formulation introduces some convective terms in the finite element equations and consists of two phases. Each time step is... 

In this work, milled Nd12.8Fe79.8B7.4-type powders with three different oxygen contents were processed into sintered anisotropic magnets via a standard powder metallurgy technique. Minimizing the oxygen content within the powder material, resulted in an almost full densification in the sintered magnets even at the lower end of the sintering temperature limit. Under this condition, the amount of hard magnetic Φ phase (Nd2Fe14B) was maximized in the structure of sintered bodies, which resulted in the highest energy density [BHmax] values. In the sintered magnets made from the powder with a higher oxygen content, full densification could only be obtained at the upper end of the sintering... 

Commercially pure nickel-titanium powders were mechanically milled in a vertical attritor mill under protective atmosphere for various times from 10 to 24 hr. Products were then compacted and sintered at different temperatures for different times. Amorphization and interatomic phase formation were determined by X-ray diffractometry, scanning electron microscopy, and differential scanning calorimetry. Porosity, virtual density, transition temperatures, and the amount of Ni3Ti first increased and then decreased with the milling time. Presence of oxygen in the milling atmosphere showed partial crystallization of NiTi intermetallic compound accompanied by titanium oxide formation  

This paper is concerned with the numerical modeling of powder cold compaction process using a density-dependent endochronic plasticity model. Endochronic plasticity theory is developed based on a large strain plasticity to describe the nonlinear behavior of powder material. The elastic response is stated in terms of hypoelastic model and endochronic plasticity constitutive equations are stated in unrotated frame of reference. A trivially incrementally objective integration scheme for rate constitutive equations is established. Algorithmic modulus consistent with numerical integration algorithm of constitutive equations is extracted. It is shown how the endochronic plasticity describes the... 

In this paper, the 3D analysis of metal powder during the cold compaction process is simulated by the finite element method based on deformation theories. Since the compaction process involves a very large reduction in volume, a large displacement finite element method is applied for the spatial discretization. During compaction, powders exhibit strain or work hardening, the volume reduces and the material becomes harder. In this study, a quasi-nonlinear analysis is carried out during the FE modelling of powder forming process. The material parameters are experimentally established as functions of relative density. These nonlinear functions are incorporated into the inelastic analysis of... 

In this paper, the numerical modeling of powder-forming process is simulated by a finite element analysis using a density-dependent endochronic plasticity model. Endochronic constitutive model based on large strain plasticity is presented. The elastic response is stated in terms of hypoelastic model and the endochronic plasticity constitutive equations are developed in unrotated frame of reference. Constitutive equations of the endochronic theory in large strain state and their numerical integrations are established. The algorithmic modulus consistent with the numerical integration algorithm of constitutive equations is extracted. Finally, the numerical schemes are examined for efficiency in...