Study of 3D MPFEM simulation for high-velocity compaction of 2024 al alloy powders

In powder metallurgy, high-velocity compaction (HVC) is one of the processes used to densify metal powders, to give them a defined shape, size, porosity, and strength. In order to achieve a green compact of 2024 Al with low porosity and high relative density, this study uses the Multi-Particle Finite Element Method (MPFEM) to simulate the 3D HVC of 2024 Al alloy powder with a particle size of 64 μm. The simulation reproduced the displacement and deformation of particles, as well as the filling of pores during the powder pressing process, effectively simulating the HVC process. The study investigates the effects of impact energy per unit mass (E_m), hammer mass (M), compaction velocity (v), and friction coefficient (µ) on the green compact density. The results indicate thatwhen E_m is increased from 45.9 J/g to 173.3 J/g, the relative density of the green compact rises from 0.72312 to 0.97193.Further research shows that, with E_m remaining constant, the impact of the hammer mass on the relative density of the compact is greater than that of the compaction velocity .The relative density of the compact with a hammer mass of M = 25 kg is 0.015952416 higher than that with M = 15 kg. In addition, the smaller µ between particles and between particles and molds during compaction helps to reduce the kinetic energy consumption, thus promoting the transfer of force from top to bottom during compaction.