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Mechanics of Powder Compaction For Ceramic Manufacturing

(1) Ceramic powders are pressed into "green" bodies prior to sintering, but density gradients can cause distortions during sintering requiring expensive machining; (2) Finite element models are being used to optimize die geometry and pressing to produce more uniform compacts; (3) The authors are measuring mechanical properties of ceramic powders under hydrostatic and triaxial compression to inform a plasticity model of powder compaction behavior.

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0% found this document useful (0 votes)
108 views

Mechanics of Powder Compaction For Ceramic Manufacturing

(1) Ceramic powders are pressed into "green" bodies prior to sintering, but density gradients can cause distortions during sintering requiring expensive machining; (2) Finite element models are being used to optimize die geometry and pressing to produce more uniform compacts; (3) The authors are measuring mechanical properties of ceramic powders under hydrostatic and triaxial compression to inform a plasticity model of powder compaction behavior.

Uploaded by

jogibhavin
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Mechanics of Powder Compaction

for Ceramic Manufacturing


Need
Ceramic powders are commonly pressed into dies to produce near-net-shape “green” bodies prior to
final sintering. Density gradients in the resulting compacts may cause distortions in the shape of the
parts during sintering , necessitating expensive machining or grinding operations to obtain the desired
final shape. Nonuniform shrinkage may even generate internal stresses that are sufficiently large to
cause fracture of the parts during sintering. Equally importantly, these density gradients can result in
green bodies that break during ejection from the die or that are too fragile to be handled.

Increasingly, finite element methods are being used to analyze the causes for density gradients in green
compacts. The ultimate objective is to develop comparatively inexpensive numerical models for the
pressing process that can optimize the die geometry and pressing method (e.g., single- versus double-
acting punches) for a given powder before a single part is even pressed.

Numerical models for the compaction process require, as inputs, constitutive models and mechanical
properties for the powder, as well as information on the frictional properties of the powder against the
die. Plasticity models developed from the
disciplines of soil mechanics and
geomechanics turn out to be well-suited for
application to the powder compaction
problem. Like soils and other granular
media, ceramic powders are pressure-
sensitive, dilatant materials whose
properties vary greatly as functions of
confining pressure and density. Substantial
differences in mechanical properties exist
from powder to powder, depending uppon
such variables as powder composition,
grain aggolmerate size and shape, binder
type and amount, etc. By their interaction
with the die during pressing, these
properties turn affect the homogeneity with
which the powder compacts.
Axial, lateral and volumetric strain response for 99.5%
alumina powder deformed at a confining pressure of 34.5 MPa
Description (5000 psi) and a strain rate of 10-4 s-1. Unload/reload cycles
appear as sharp drops in the stress difference.
The initial objective of this work has been
to obtain mechanical property data in
hydrostatic and triaxial compression for
several different ceramic powders. Powders
are first pressed hydrostatically in cylindrical
rubber jackets to differing final pressures in
order to obtain pressure-density relationships.
From these pressing experiments, a suite of
triaxial test specimens results. The powder
compacts are machined into right circular
cylinders, and each specimen is tested in
deviatoric loading at a confining pressure
corresponding to the last pressure “seen”
during the hydrostatic testing stage.

In addition to the stress-strain response, the


bulk modulus, Young’s modulus and
Poisson’s ratio are determined using unload/
reload cycles performed many times during
the course of each test. Shear modulus is Evolution of the “cap” for a 94% alumina powder as inferred
calculated from the other parameters, from movement of surfaces of constant volume strain.
assuming material isotropy. Shear failure
surfaces are determined for each powder, and
the shape of the “cap” can be inferred from the data, as well. Over the range of pressures that we have
investigated (3.4-69 MPa), the various elastic parameters are functions of pressure and density; they also
vary systematically with deviatoric strain during the course of a single test.

Examples
We have shown that differences in mechanical properties, shear failure surfaces and cap shapes are
detectable and systematic for different alumina powders in both hydrostatic and triaxial compression
[Zeuch et al., 1998; in preparation]. The experimental results are also currently being used in the “Sandia
cap model”, a modified Drucker-Prager cap-plasticity model. The model is implemented using finite
element methods, in order to estimate the effects of the differing mechanical properties on pressing
results for simple die geometries [Argüello et al., 1998]. Work is in progress to characterize a zirconia
powder.

The next stage of the experimental program will entail careful testing to identify the specific factor(s)
responsible for the differences in mechanical properties amongst ceramic powders. We will also attempt
to confirm the model predictions by direct investigation of density gradients in the resulting compacts.

References
Argüello, J. G., A. F. Fossum, K. G. Ewsuk and D. H. Zeuch [1998]. Powder Compaction Simulation
Using Finite Element and Cap Plasticity Constitutive Laws. Presented at the 100th Annual Meeting of
the American Ceramic Society, 3-6 May 1998, Cincinnati, Ohio.

Zeuch, D. H., J. M. Grazier, K. G. Ewsuk and J. G. Argüello [1998]. Comparison of the Mechanical
Properties of Micron- and Submicron Size Alumina Powders. Presented at the 100th Annual Meeting of
the American Ceramic Society, 3-6 May 1998, Cincinnati, Ohio.
Zeuch, D. H., J. M. Grazier, J. G. Argüello and K. G. Ewsuk [in preparation]. Measurement of the Mechanical
Properties and Shear Failure Surfaces of Two Alumina Powders in Triaxial Compression. To be submitted
the Journal of the American Ceramic Society.

Contacts
David H. Zeuch J. Guadalupe (Lupé) Argüello
Geomechanics Department Engineering and Manufacturing Mechanics Department
Sandia National Laboratories Sandia National Laboratories
Albuquerque, NM 87185-0751 Albuquerque, NM 87185-0437
Telephone: (505) 844-6829 Telephone: (505) 844-1482
Fax: (505) 844-7354 Fax: (505) 844-9297
e-mail: [email protected] e-mail: [email protected]

Kevin G. Ewsuk
Materials Processing Department
Sandia National Laboratories
Albuquerque, NM 87185-1349
Telephone: (505) 272-7620
Fax: (505) 272-7304
e-mail: [email protected]

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