Modeling of Conductivity Versus Density Behavior in Green-State Powder Metallurgy Compacts

Abstract

Ongoing research at Worcester Polytechnic Institute (WPI) has recently resulted in the development of an electrostatic multipin instrument capable of testing green-state compacts directly after compaction. By monitoring a steady electric current flow through the sample and recording the voltages over the surface valuable information is gathered, leading to the prediction of the structural health of the green-state parts. Whereas our prior work concentrated on the detection of surface-breaking and subsurface defects, which requires the determination of large differences in material properties over small flaw sizes, the results presented in this paper aim at the density prediction throughout the volume of the sample. This requires the detection of small changes in material properties over large regions. A physical model and a mathematical formulation are reported, which are capable of relating green-state density changes to electric conductivity in the presence of various lubricant concentrations. Preliminary electrostatic measurements of cylindrical compacts have thus far confirmed the theoretical model assumptions, showing that the electric conductivity follows a complex graphical behavior that is determined by the type and concentration of the lubricant. Specifically, the green state conductivity increases as the sample density increases up to values of approximately 6.9 to 7.0 g/cm3. Any further density increase, however, results in a decrease in conductivity.