Modelling and Simulation of the Electrical Resistance Sintering Process of Iron Powders

Abstract

In this paper, the process known as Electrical Resistance Sintering under Pressure is modelled, simulated and validated. This consolidation technique consists of applying a high-intensity electrical current to a metallic powder mass under compression. The Joule efect acts heating and softening the powders at the time that pressure deforms and makes the powder mass to densify. The proposed model is numerically solved by the fnite elements method, taking into account the electrical–thermal–mechanical coupling present in the process. The theoretical predictions are validated with data recorded by sensors installed in the electrical resistance sintering equipment during experiments with iron powders. The reasonable agreement between the theoretical and experimental curves regarding the overall porosity and electrical resistance suggests that the model reproduces the main characteristics of the process. Also, metallographic studies on porosity distribution confrm the model theoretical predictions. Once confrmed the model and simulator efciency, the evolution of the temperature and the porosity felds in the powder mass and in the rest of elements of the system can be predicted. The infuences of the processing parameters (intensity, time and pressure) as well as the die material are also analyzed and discussed.