Compaction modeling and physicomechanical characterization of LM26 alloy powder via powder metallurgy

This study investigates the densification behavior and mechanical properties of LM26 aluminum alloy powder subjected to various compaction pressures in powder metallurgy. The powder's flowability and compressibility were evaluated using the angle of repose, Carr's index, and Hausner ratio, confirming its suitability for compaction processes. Particle characterization through dynamic light scattering, energy‐dispersive x‐ray spectroscopy, field emission scanning electron microscopy, and x‐ray diffraction revealed insights into particle size, elemental composition, morphology, and crystalline phases. Green density, determined by mass‐to‐volume ratio, ranged from 77.45 % to 96.02 % at pressures of 100 MPa–550 MPa, with a notable linear relationship between applied pressure and density. The Panelli and Ambrosio Filho model best described the compressibility behavior. Mechanical testing showed significant increases in Vickers hardness, reaching 42.89 HV 0.2 for cube specimens at 550 MPa and 44.12 HV 0.2 for cuboid specimens at 250 MPa. Flexural strength reached a peak of 30.44 MPa at 250 MPa, highlighting the benefits of higher compaction pressures. Weibull distribution analysis confirmed the uniformity and reliability of hardness and strength characteristics, reinforcing the applicability of powder metallurgy for structural applications.