A novel method to improve the critical damage parameter of powder metallurgical components during the cold upsetting

Abstract

In the metal forming process, the understanding of metal flows and the fracture strains are most significant to the failure/damage of the components. Usually, in metalworking, damage occurs because of nucleation, growth and coalescence of the void into a small fracture. These small fractures increased in the circumferential path due to the existence of stresses and the pores which leads to failure at the equatorial position during the upsetting of porous samples. Hence, the fracture of the workpieces strongly depends on the stresses and the pores. Such form of stresses and pores if relieved will give a better damage limit of the material. Therefore, in this research, a novel scheme of localised heating is adopted at the equatorial position of the compressed samples to enhance the critical damage parameter. The powder metallurgy route was used to prepare the required compacts with different relative densities (80%–90%) and 1 aspect ratio by applying suitable powder forming pressures. The upsetting test was performed on the obtained porous samples for various weight percentages of titanium (2%–6%) in the aluminium at the stable strain rate (0.1 s⁻¹) and the damage location was noticed for various components. After the identification of damage position, various temperatures (100 °C–250 °C) of localised heating were attempted on the failure site of the specimens after some incremental stages of upsetting tests. The experimental results were analysed using various damage criteria and it was found that the initiation of failure is delayed and increased the critical damage value by selectively heating the samples because of relieving the stresses, reduction in porosity and changes in microstructure.