scholarly journals Electro Sinter Forging (ESF)

Micromachines ◽  
2019 ◽  
Vol 10 (4) ◽  
pp. 218 ◽  
Author(s):  
Emanuele Cannella ◽  
Chris Valentin Nielsen ◽  
Niels Bay
Keyword(s):  
Process Parameters ◽  
Compaction Pressure ◽  
Pure Titanium ◽  
Electrical Current ◽  
Main Process ◽  
Commercially Pure Titanium ◽  
Electrical Currents ◽  
Sinter Forging ◽  
Sintering Time ◽  
Electrical Current Density

Electro sinter forging (ESF) represents an innovative manufacturing process dealing with high electrical currents. Classified in the category of electrical current assisted sintering (ECAS) processes, the main principle is that Joule heating is generated inside the compacted powder, while the electrical current is flowing. The process is optimized through the analysis of the main process parameters, namely the electrical current density, sintering time, and compaction pressure, which are also evaluated as process fingerprints. The analysis was conducted on commercially pure titanium powder. Small discs and rings were manufactured for testing. The influence of the process parameters was analysed in terms of the final material properties. The relative density, microstructures, hardness, and tensile and compressive strengths were analysed concerning their validity as product fingerprints. Microstructural analyses revealed whether the samples were sintered or if melting had occurred. Mechanical properties were correlated to the process parameters depending on the material. The different sample shapes showed similar trends in terms of the density and microstructures as a function of the process parameters.

scholarly journals Lubricant Influence on the Ejection and Roughness of In-Die Electro Sinter Forged Ti-Discs

2018 ◽  
Vol 767 ◽  
pp. 171-178 ◽  
Author(s):  
Emanuele Cannella ◽  
Chris Valentin Nielsen
Keyword(s):  
Surface Defects ◽  
Pure Titanium ◽  
Roughness Parameter ◽  
Axial Loading ◽  
Electrical Current ◽  
Radial Pressure ◽  
Sintered Sample ◽  
Commercially Pure Titanium ◽  
Mechanical Pressure ◽  
Sinter Forging

Electro Sinter Forging (ESF) is a new sintering process based on Joule heating by high electrical current flowing through compacted metal powder under mechanical pressure. The whole process takes about three seconds and is based on a closed-die setup, where the sample is sintered inside a die. A near-net shape component is therefore manufactured. One of the challenges associated with this process is the ejection of the sample after sintering. Due to powder compaction and axial loading during sintering, a radial pressure is generated at the die/sample interface. Consequently, the ejection can be difficult, and the final quality of the sintered component in terms of roughness and surface defects may be affected. In the present work, four different lubricants and non-lubricated conditions were tested to investigate the effects on the final part quality. The sintered sample is a disc made of commercially pure titanium powder. The force was measured while ejecting the samples by using a speed-controlled press. The surface roughness parameter Sa was measured by using a laser confocal microscope.

scholarly journals Effects of Process Parameters On Tool Vibration And Force Transmissibility In High-Speed Micro-Milling Machine

2021 ◽  
Author(s):  
Chitransh Singh ◽  
Arnab Das ◽  
Vivek Bajpai ◽  
Madan Lal Chandravanshi
Keyword(s):  
Process Parameters ◽  
High Speed ◽  
Pure Titanium ◽  
Cutting Speed ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Commercially Pure Titanium ◽  
Axial Thrust ◽  
Tool Vibration ◽  
Radial Thrust

Abstract High-speed micro-milling is an emerging technology used to produce micro and miniaturized products with smooth surface finish and high dimensional precision. However, tool vibration is a major problem in micro-milling as it directly affects the product accuracy, surface quality and tool life. Inappropriate selection of process parameters increases radial and axial thrust as well as force transmitted to structure during micro-machining which results in rapid tool vibration. This work focuses on the experimental investigation of process parameters (cutting speed and depth of cut) in order to reduce tool vibration due to axial and radial thrust in high-speed micro-milling. The tool used in this experiment is a 2-flute end mill cutter (1 mm cutter diameter) and workpiece is a commercially pure titanium (CpTi) plate. The operation was performed at different depth of cut and varying cutting speeds keeping the chip load constant. Vibration signals were acquired and processed to obtain the vibration thrust of the tool and the force transmitted to the structure. The results indicated that as the depth of cut and cutting speed increases, both axial as well as radial thrust decreases leading to lower vibration amplitude of the cutting tool and reduction in force transmitted to the machine structure.

Effect of process parameters on hardness and microstructure of graphene reinforced titanium composites

2017 ◽  
Vol 52 (4) ◽  
pp. 543-551 ◽  
Author(s):  
Mevlüt Gürbüz ◽  
Tugba Mutuk
Keyword(s):  
Titanium Carbide ◽  
Process Parameters ◽  
Pure Titanium ◽  
Carbide Formation ◽  
Strengthening Mechanisms ◽  
Fine Grain ◽  
Fine Grain Strengthening ◽  
Sintering Time ◽  
First Time ◽  
Composite Properties

In this study, the effect of the sintering time, temperature and graphene amount on titanium properties was examined for the first time in detail. From the results, the highly dense (4.39 g/cm3), most hard (from 390 HV to 566 HV) and improved microstructure for 0.15 wt% graphene addition were performed at 1100℃ for 120 min. The titanium composite properties have been reduced with increasing graphene due to damaged graphene and titanium carbide formation above 0.30 wt% graphene. To summarise, when pure titanium is compared with graphene reinforced titanium composites, the properties enhanced due to dislocation and fine grain strengthening mechanisms.

Optimization of powder metallurgy parameters of TiC and B4C reinforced aluminium composites by Taguchi method

2020 ◽  
Author(s):  
Vairamuthu J ◽  
Senthil Kumar A ◽  
Stalin B ◽  
Ravichandran M
Keyword(s):  
Composite Material ◽  
Powder Metallurgy ◽  
Process Parameters ◽  
Compression Strength ◽  
Metal Matrix ◽  
Sintering Temperature ◽  
Compaction Pressure ◽  
Input Process ◽  
Sintering Time ◽  
Metal Matrix Composite Material

In this paper, the aluminium based metal matrix composite material has been developed via powder metallurgy (PM) route by considering the various input process parameters. Sintering time, sintering temperature and compaction pressure are the three main factors used as input process parameters which are varied at three levels. Investigations have been planned with reference to the experimental design of L9 orthogonal array using a 3x3 matrix. The density, Vickers hardness and compression strength are experimented and analyzed. The influence of individual input parameters has been analyzed using Taguchi based S/N ratio and analysis of variance (ANOVA). The optimum parameter levels to achieve less density, high hardness and high compressive strength were identified through the main effect plots. Experimental results indicate that the sintering temperature and compaction pressure highly influences properties such as density and hardness. Similarly, compression strength mainly depends on sintering time and sintering temperature. Through ANOVA analysis, it was also confirmed that the selected parameter levels of the optimum sintering time at an average compaction pressure and sintering temperature will produce the best metal matrix composite material.

Parametric optimization of EDD using RSM-Grey-TLBO-based MCDM approach for commercially pure titanium

2020 ◽  
Vol 10 (2) ◽  
pp. 231-245
Author(s):  
Neeraj Sharma ◽  
Neeraj Ahuja ◽  
Rachin Goyal ◽  
Vinod Rohilla
Keyword(s):  
Process Parameters ◽  
Parametric Optimization ◽  
Pure Titanium ◽  
Multicriteria Decision Making ◽  
Electrode Wear ◽  
Commercially Pure Titanium ◽  
Content Type ◽  
Commercially Pure ◽  
Pulse On Time ◽  
Pulse Off Time

PurposeElectric discharge drilling (EDD) is used to drill quality microholes on any conductive materials. EDD process parameters play a crucial role in the drilling. Depending upon the material characteristics, the cost of drilling also changes. Therefore, a suitable method is required to control the process parameters and drill quality microholes.Design/methodology/approachThe input process parameters in the present work are peak current (Ip), pulse on-time (Ton) and pulse off-time (Toff). The trials were intended in accordance to central composite face-centered design of response surface methodology (RSM). The output responses, namely drilling rate (DR) and electrode wear ratio (EWR), were converted into a single response, that is, grade using Grey relational analysis (GRA). The grade value is further modeled by regression analysis. The empirical model was figured out using teaching–learning-based optimization (TLBO). The RSM-Grey-TLBO-based multicriteria decision-making (MCDM) is used to investigate the optimized process parameter setting.FindingsThe RSM-Grey-TLBO-based MCDM approach suggests that the optimized setting for DR and EWR is Ip: 3A; Ton: 40 µs; Toff: 42 µs. The percentage errors for the predicted and experimental results are 8.1 and 7.5% in DR and EWR, respectively.Originality/valueThe parametric optimization of EDD using RSM-Grey-TLBO-based MCDM approach while machining commercially pure titanium is still underway. Thus, this MCDM approach will give a path to the researchers working in this direction.

scholarly journals Powder Metallurgy Synthesis of Heusler Alloys: Effects of Process Parameters

Materials ◽  
2019 ◽  
Vol 12 (10) ◽  
pp. 1596 ◽  
Author(s):  
Riaz Ahamed ◽  
Reza Ghomashchi ◽  
Zonghan Xie ◽  
Lei Chen
Keyword(s):  
Process Parameters ◽  
Heusler Alloy ◽  
Powder Processing ◽  
Compaction Pressure ◽  
Heusler Alloys ◽  
Processing Condition ◽  
Vacuum Induction Melting ◽  
Processing Route ◽  
Induction Melting ◽  
Sintering Time

Ni45Co5Mn40Sn10 Heusler alloy was fabricated with elemental powders, using a powder processing route of press and sinter, in place of vacuum induction melting or arc melting route. The effects of process parameters, such as compaction load, sintering time, and temperature, on the transformation characteristics and microstructures of the alloy were investigated. While the effect of compaction pressure was not significant, those of sintering time and temperature are important in causing or annulling martensitic transformation, which is characteristic of Heusler alloys. The processing condition of 1050 °C/24 h was identified to be favorable in producing ferromagnetic Heusler alloy. Longer durations of sintering resulted in an increased γ-phase fraction, which acts as an impediment to the structural transformation.

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