FEM modeling on the compaction of Fe and Al composite powders

Abstract

The compaction process of Fe and Al composite powders subjected to single action die compaction was numerically modeled by FEM method. The relationship between the overall relative density and compaction pressure of the compacts with various Al contents was firstly identified, and the influences of Al content on the local relative density, stress, and their distributions were studied. Then the compaction pressure effects on the above properties with fixed Al content were discussed. Furthermore, detailed flow behaviors of the composite powders during compaction and the relationship between the compaction pressure and the ejection force/spring back of the compact were analyzed. The results show that: (1) With each compaction pressure, higher relative density can be realized with the increase of Al content and the relative density distribution tends to be uniform; (2) When the Al content is fixed, higher compaction pressure can lead to composite compact with higher relative density, and the equivalent Von Mises stress in the central part of the compact increases gradually; (3) Convective flow occurs at the top and bottom parts of the compact close to the die wall, each indicates a different flow behavior; (4) The larger the compaction pressure for each case, the higher the residual elasticity, and the larger the ejection force needed.

Experimental and numerical investigation of densification behaviors during powder compaction

“…An approximately linear stress decrease along the direction from top punch to bottom punch exists in the center part of the compacted parts. The Von Mises stress distribution of this multi-particle finite simulation is in good agreement with others continuum simulations and experimental results (Diarra et al, 2012, Sethi et al, 2013, Han et al, 2015. The characteristic stress distribution of compacted part is a macroscopic representation of massive frictional interactions and plastic deformations of powder particles, the densification analysis using multi-particle finite element method brings about more convenience to investigate the plastic deformation behaviors of an individual particle in the overall macroscopic stress field.…”

“…At present, three numerical approaches are available for densification analysis of powder compaction, which are continuum finite element analysis, discrete element analysis and multi-particle finite element analysis. The continuum finite element analysis considers the compacted part as a continuous media with a certain percent of gas porosity, it can describe the macroscopic densification behaviors, but lack of detailed microscopic information, such as the particle deformation, displacement path and inter-particle frictional interactions (Lewis and Khoei, 1998, Gao et al, 1999, Han et al, 2015. The discrete element analysis treats each powder particle as a rigid body without any plastic deformation.…”

Review of Iron Recovery and Cleaning of Copper Slag

“…7, in the grinding and beneficiation stages, a copper recovery of 48.8% and a copper concentrate grade of 14.26 mass% were achieved; an iron concentrate grade of 54.76 mass% and iron recovery of 65.81% were also obtained. 6) Actually, copper slag flotation is the same as sulfide ore flotation. This means that only metallic copper and sulfide minerals can be floated effectively.…”

Double-action Die Compaction of Fe-Al Composite Powder- A Study by MPFEM Simulation

“…In recent years, Fe-Al intermetallic compounds are attractive due to their unique properties such as low cost, low density, ease of fabrication, good high temperature mechanical property, excellent resistance to oxidation and corrosion, high electrical resistivity, as well as dual characteristics of both structural and functional materials etc [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18]. These properties have led to the identification of many potential uses, including high temperature structural materials, sintered porous gas-metal filters, heating elements, furnace fixtures, heat-exchanger piping, automobile and other industrial valve components, catalytic converter substrates, and components for molten salt applications [3][4][5]9,19,20].…”

“…While they are mainly focusing on the compaction of ordered initial packing structures, for the compaction of random initial packings which are frequently appeared in real process is not studied in their work. Recently, using traditional finite element method (FEM) and multi-particle FEM (MPFEM) method, Han et al respectively carried out systematic studies on the single-action die compaction of Fe-Al composite powders with random initial packing structures from both continuous scale and discrete scale [17,18]. In their work, the macro and micro properties of the compacts as well as the densification mechanisms were characterized and analyzed.…”