Anisotropic Tensile and Compressive Strengths of Al–4 wt.%Cu Alloy Powder: Part 1—Effects of Compaction Loads and Heat Treatments

Powder metallurgy stands out as a preferred manufacturing method across various industries due to its advantages in design flexibility, material efficiency, and cost-effective production. In this work, we study the influence of different compaction directions on the strength characteristics of parts produced using powder metallurgy. Al–4 wt.%Cu alloys are used due to their recyclability. We use three distinctive compaction pressures. After sintering, samples are either air-cooled or water-quenched and naturally aged (T4 temper). Both the compressive and tensile strengths are characterized and thoroughly analyzed. This research highlights the significant impact of both heat treatments and compaction directions on anisotropic strengths. The novelty of this research lies in the use of powders that can be reclaimed from machining, turning, or foundry rejections. By eliminating or minimizing the melting stage and employing powder metallurgy, we achieve cost-effective and environmentally friendly processes. Furthermore, we underscore the critical role played by careful planning of compaction loads, compaction directions, and heat treatments in determining the final mechanical performance. This approach is not only economically viable but also aligns with the growing adoption of environmental, social, and governance (ESG) practices in industry.