Modelling and Simulation of the Electrical Resistance Sintering Process of Iron Powders

In this paper, the process known as Electrical Resistance Sintering under Pressure is modelled, simulated and validated. This consolidation technique consists of applying a high-intensity electrical current to a metallic powder mass under compression. The Joule effect acts heating and softening the powders at the time that pressure deforms and makes the powder mass to densify. The proposed model is numerically solved by the finite elements method, taking into account the electrical–thermal–mechanical coupling present in the process. The theoretical predictions are validated with data recorded by sensors installed in the electrical resistance sintering equipment during experiments with iron powders. The reasonable agreement between the theoretical and experimental curves regarding the overall porosity and electrical resistance suggests that the model reproduces the main characteristics of the process. Also, metallographic studies on porosity distribution confirm the model theoretical predictions. Once confirmed the model and simulator efficiency, the evolution of the temperature and the porosity fields in the powder mass and in the rest of elements of the system can be predicted. The influences of the processing parameters (intensity, time and pressure) as well as the die material are also analyzed and discussed. Graphic abstract