Abstract
This paper presents a numerical and experimental analysis of manufacturing of intermetallic ceramic composites by powder metallurgy techniques. The scope of the paper includes the formulation and development of an original numerical model of powder metallurgy of two-phase material within the framework of the discrete element method, simulations of powder metallurgy processes for different combinations of process parameters, and a verification of the numerical model based on own experimental results. Intermetallic-based composite NiAl–AlO has been selected as representative material for experimental and numerical studies in this investigation. Special emphasis was given to the interactions between the intermetallic and ceramic particles by formulating the special model for adhesive contact bond. In order to properly represent a real microstructure of a two-phase sintered body, a discrete element specimen was generated using a special algorithm. Numerical validation showed the correct numerical representation of a sintered two-phase composite specimen. Finally, micromechanical analysis was performed to explain the macroscopic behavior of the sintered sample. The evolution of the coordination number, a number of equilibrium contacts, and the distribution of the cohesive neck size with respect to time are presented.
Highlights
Powder metallurgy (PM) is a technology commonly used for manufacturing metal, ceramic or composite materials applicable in many industrial branches
This paper presents a numerical modeling of a powder metallurgy process of a two-phase powder mixture validated with our own experimental results
The numerical model of the powder metallurgy process for composite materials was developed within the framework of the discrete element method, with spherical discrete elements representing powder particles
Summary
Powder metallurgy (PM) is a technology commonly used for manufacturing metal, ceramic or composite materials applicable in many industrial branches. The elastic and viscous effects in the particle interaction during sintering have been taken into account, which ensured a much better efficiency This model has been further enriched by the application of Hertz contact model interaction between the powder particles, which brought more realistic numerical results in comparison to experimental ones [19]. This formulation has been successfully employed to model a hot pressing process with its main stages: Initial powder compaction and pressure-assisted sintering within one simulation [20]. The numerical investigation has been carried out for a powder metallurgy process performed to manufacture a composite with the NiAl intermetallic matrix reinforced with Al2 O3 ceramics. The calibrated model was validated by numerical simulations performed for different process parameters and by comparing the numerical and experimental results
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