Center for Advanced Vehicular Systems

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Computer and mathematical based modeling of the thermo-mechanical behavior of metal powders during compaction and sintering densification processes is recognized as a significant contribution to improving efficiency, quality and cost of current production and to generating new business opportunities for powder metallurgy industry. Here, we evaluate and develop numerical modeling techniques to predict mechanical properties throughout P/M component sections. The transition of current materials/design requirements to advanced structural P/M components has created a need to predict the properties of components in all sections of design. In addition, design processes should consider the least cost, lowest mass product designs and reduced development lead-time. We extend existing math-based frameworks with the abilities to predict P/M component structures and properties accurately throughout the compaction and sintering processes (section size, density variation, dimensional tolerances, potential for cracking), and with the input of alloys and process parameters (machine functions, tool and powder temperatures, friction and pressure). The history of a P/M part is captured through its pressing, sintering, and life-cycle performance using a developed multiscale methodology. The final goal is to determine quality control process factors (powder properties, press settings, tooling design, and furnace conditions) for P/M parts production in terms of design and performance optimization, and of their impact on process variations and quality improvement.