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Formability modelling of aluminium base PM alloys


Foreseen Results

Expected achievements and benefits of the project are:
A consistent description of material behaviour, which will establish a reference knowledge base;
A proof of constitutive relations applicability for the target alloys;
A better understanding of correlation between process parameters and the achievable product specifications in terms of resistance and quality will lead to a better production control;
Improvement of product quality;
Extension of the application area of PM products;
Sensitizing the target industry branches about the feasibility of PM products production;
Stimulation of the development of a scrap-free manufacturing method;
Contribution towards development of a technology which can use recycled materials;
Acceleration of modernization in a high technology sector.

The exploitation of the project results will have a stimulating effect on the industry in the involved Central European
countries. The target group of industrial companies has got already several interested members, which have provided letters of endorsement.
Powder metallurgy parts, a result of consolidation of metal powders into various shapes using pressed compaction of powder in precisely shaped metal dies, provides a means for generating low-cost parts for high-volume, small parts applications. CAB of powder metallurgy processes has been doing progresses by development of material models which allow the simulation of evolution in critical phases like compaction, sintering and forging. The Finite Element Method has established itself as the most efficient and flexible one. However, attention is continuously given to the characterization of the material properties at the micro- and macro-structural level, in order to make a realistic estimation of key parameters of the mathematical model, which are at the base of formability estimation by FEA. The application of PM aluminium base alloys is still dependent on the correct evaluation of the formability and of aspects related to the physical metallurgy of the process. Systematic research is still to be done, both theoretically and experimentally in order to build a scientific fundament in this area. Validation of the process mechanisms by simulation will eventually extend the interest of manufacturing industry.
In Hungary, Slovakia and Poland powder metallurgy has a long tradition. Although, the level of industrial application of A1 base PM alloys is low, in comparison with other European and non-European countries like Japan and USA. Scientific cooperation within the project will have a synergetic effect by bringing together professionals from five European countries, who will provide complementary expertise and will contribute actively towards development in a sensitive area of production technology. The project will be done on already existing basis facilities.
Assessment of formability will be made on the basis of experimental research of two relevant PM aluminium alloys with high contents of silicium. The research will be carried out on two parallel levels: experimental and theoretical. On the experimental level, fabrication of PM products by extrusion-type compaction will be done. A comprehensive microstructural analysis of the powders used and of the compacted specimens (optical microscopy, TEM, SEM, X-ray analysis) will provide data which, together with mechanical testing (strength, hardness, ductility, tenacity, fatigue), can describe the correlation between the fabrication process parameters and representative product characteristics. Material data regarding the inelastic behaviour of compacted material under external loading (flow curves in different loading/unloading schemes, toolworkpiece interface characteristics) will be the base of the FEM analysis of the process. A further die-forging operation will be performed on compacted bar workpiece into a connection rod shape. Numerical simulation of this operation will be made. Conclusions will be drawn regarding the influential factors of the formability of the studied PM aluminium alloys.

Funding Scheme

CSC - Cost-sharing contracts


1A,welfengarten 1
30167 Hannover

Participants (4)

97,Kleine Houtstraat 97
7500 DT Enschede
47,Watsonova 47
043 53 Kosice
Technical University of Budapest
1-3,Múegyetem Rkp.
1521 Budapest
University of Mining and Metallurgy
30,Al. Mickiewicza 30
30 059 Kraków