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Process investigation and mechanical properties of electro sinter forged (ESF) titanium discs

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Abstract

Classified as an electric current–assisted sintering (ECAS) process, electro sinter forging (ESF) represents a sintering process following the resistance heating approach. The powder is simultaneously compacted and heated in a closed-die setup. The heating is generated by the Joule effect from the electrical current. Near net shape components of conductive materials are made in the closed-die setup within a short process time (100–400 ms). The final relative density is an important quality measure for the sintered parts. In the present work, samples of commercially pure titanium are produced with up to 98% relative density by optimisation of the main process parameters, namely electrical current density, compaction pressure and sintering time. Metallographic observations revealed that porosities were mostly found at the perimeter of the sintered samples. Mechanical testing by μ-Vickers hardness test, uniaxial compression and indirect tensile tests showed improved properties of the material with increasing density. The achieved mechanical properties were compatible with the theoretical values for bulk titanium.

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Abbreviations

ASTM:

American Society for Testing and Materials International

bcc:

Body-centred cubic

BSD:

Backscattered detector

ECAS:

Electric current–assisted sintering

ESF:

Electro sinter forging

FAST:

Field-assisted sintering technology

GUM:

Guide to the expression of uncertainty in measurement

hcc:

Hexagonal close-packed

HP:

Hot pressing

HV:

Hardness Vickers

IDT:

Indirect tensile test

ISO:

International Organization for Standardization

LOM:

Light optical microscopy

MFDC:

Middle-frequency direct current

SEM:

Scanning electron microscope

SPS:

Spark plasma sintering

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Acknowledgements

This research work was undertaken in the context of MICROMAN project (“Process Fingerprint for Zerodefect Net-shape MICROMANufacturing”, http://www.microman.mek.dtu.dk/). MICROMAN is a European Training Network supported by Horizon 2020, the EU Framework Programme for Research and Innovation (Project ID: 674801).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Technical University of Denmark, Produktionstorvet 425, DK-2800, Kgs. Lyngby, Denmark

    Emanuele Cannella, Chris Valentin Nielsen & Niels Bay

  2. IPU, Diplomvej 376, DK-2800, Kgs. Lyngby, Denmark

    Emanuele Cannella

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  1. Emanuele Cannella
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Correspondence to Chris Valentin Nielsen.

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Cannella, E., Nielsen, C.V. & Bay, N. Process investigation and mechanical properties of electro sinter forged (ESF) titanium discs. Int J Adv Manuf Technol 104, 1985–1998 (2019). https://doi.org/10.1007/s00170-019-03972-z

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