Experimental and numerical investigations on electromagnetic powder compaction of Aluminium 6061 alloy powder

The present research's objective is to investigate the electromagnetic radial powder compaction process and its effect on the densification, microstructure and mechanical properties of the Al 6061 alloy powder. Cylindrical product has been prepared from Al 6061 powder using the electromagnetic powder compaction method. In this method, electromagnetic force shrinks the packing tube and utilises the deformation of the tube to compact the Al 6061 powder. The electromagnetic forces were generated between the field shaper's inner cylindrical surface and the outer surface of the packing tube when a high voltage current is flowing through the solenoid coil. In this study, the Al 6061 powder is compacted at various discharge voltages such as 13 kV, 14 kV, 15 kV and 16 kV using a 20 kV and 40 kJ capacity electromagnetic forming machine. Sintering is performed on the compacted samples at 620 °C for 1 h in an N₂ tubular furnace. The simulation was carried out using loosely coupled multi-physics software, and simulated results were validated with the experimental results. Ansys Maxwell is used to analyse the electromagnetic field, and Ls-Dyna is used for structural analysis. To describe the deformation behaviour of the packing tube, the Cowper –Symonds model was used. The deformation in the compact and stress-strain variation was analysed using simulation results and experimental results. The effect of field shaper on powder compaction is investigated using the magnetic field analysis of the Ansys Maxwell results. The velocity of the packing tube is analysed for various input discharge voltages. The Vickers micro-hardness of electromagnetic powder compacted samples increases with compaction voltage. Finally, the results predicted by numerical simulation were verified with experimental results and found in good agreement.