Surface rolling was employed to fabricate a densified layer on a powder metallurgy (PM) Fe-2Cu-0.6C piece. A densified surface layer with a depth of 335 μm and a surface hardness of 330 HV 0.1 was obtained, in which the lamellar spacing of pearlite and grain size of ferrite were refined. Friction and wear behaviours of the surface densified material were studied. Results indicated that friction coefficient of the rolled material decreased as the load increased, which was lower than that of the un-rolled material. Wear volumes were lower than that of the un-rolled material, which increased as the load increased. Wear loss was caused by flake spalling and grooves, and the wear mechanism mainly was abrasive wear. The surface densified layer with higher hardness and lower porosity can hinder the cracks initiation and propagation on the surface and under the surface, which enhance the wear resistance of the PM material.
To enhance the impact energy of powder high-velocity compaction (HVC) and thus improve the green density and mechanical properties of the resulting compacts, a mechanical energy storage method using combination disc springs is proposed. e high impact energy is achieved by modifying existing equipment, and the hydraulic control system is developed to implement the automatic control of the energy produced from the disc springs. An interdisciplinary cosimulation platform is established using the ADAMS, AMESim, and LabVIEW software packages to perform the interactive control of the simulation process and the realtime feedback of the simulation results. A mechanical-hydraulic cosimulation of the energy control virtual prototype of the testing machine is conducted using this platform. e influence of the impact energy on the green density is studied according to the HVC experimental results of the iron-based powders, and then, the green compact with the higher relative density is produced. e experimental results indicate that the energy enhancement method using the combination disc springs is reasonable and that the hydraulic control scheme is reliable.
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