The current work evaluates cross-sectioned green bilayer powder compact (green BPC) of iron (Fe) under different die conditions. At first, finite element-based (FE) simultaneous compaction modelling is used to model the uniaxial, one-sided compaction of the green BPC of Fe and its interface. A Tri-mesh of 0.03 mm and mesh refinement along the interfacial boundary is set up with the condition of each node from both sides of layers (namely lower layer, L and upper layer, U) is mapped precisely to ensure its mutual interconnection along the horizontal edges of interface. Additionally, the modelling part utilised and validated our recently proposed image analysis under the metallographic technique’s standard framework. Our approach to model the interface to gain the same effect as from the experimental result of green BPC of Fe is in good agreement. It is significantly found that the use of the lubricated die condition contributed to increasing the local RD distribution along the interface of the green BPC of Fe. In contrast, the distribution is gradually dissuaded from the interface for the unlubricated die condition as the applied height: diameter (H:D) ratio increases.

A new particle method, namely the Moving Particle Pressure Mesh (MPPM) method is developed to compute incompressible single- and multi-fluid flows. Unlike the conventional particle method (such as SPH and MPS) whereby the pressure variable is associated with individual moving particle, the pressure is treated as a field (or Eulerian) variable due to the fact that there is no transport equation of pressure can be expressed for an incompressible moving fluid particle. A more accurate method can then be easily devised to evaluate the pressure gradient, which is important in governing the subsequent motion of individual fluid particle. The method is applied to compute several incompressible flow cases and the numerical results agree considerably well with the reference solutions.

The study of densification on the porous surface of cross-section bilayer Iron powder compact was covered in this work. Both manipulated layers consisted of similar mechanical properties of powder with a mass of 10 grams applied and compacted under three different force magnitudes in a lubricated die condition. Three samples of bilayer were prepared according to the different load applied on the upper layer, 95 kN, 75 kN, and 55 kN. A load of 30 kN was then applied to the lower layer of iron for all labeled samples. Resulted thickness of a 10 mm bilayer sample was obtained after employing a one-sided double compression technique within rigid die. The consequence of navigation on its cross-section, which included the top, middle, and bottom regions was performed manually using an optical microscope. The results revealed that the first layer (or bottom layer), which was compacted by applying a minimum of 30 kN and the second layer (or upper layer), which was compacted by three different specified loads, possessed a lower percentage in porosities. However, the highest load of 95 kN on the second layer displayed homogeneous densification around the interface, that is, 0.95 in which is near to full relative density.

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Cocoa powder is an important ingredient in the confectionery industry and, mannitol is an alternative sugar alcohol. In this work, mannitol powder was mixed with cocoa powder and compacted into tablet form via the uniaxial die compaction process. The frictional, compaction, tablet mechanical and disintegration properties were studied due to their importance in characterizing the behaviour of the tablets during processing and its final product characteristics at varying mannitol contents. The composition of mannitol in the mannitol-cocoa tablet varied at 95% w/w, 50% w/w and 5% w/w, while pure 100% w/w mannitol and cocoa tablets were set as controls. The compaction pressures used in making the tablets varied at 37.67 MPa, 75.34 MPa, 113.01 MPa, 150.68 MPa and 188.35 MPa. The compaction behaviour of the powder during the compaction process was evaluated using the plastic work and the maximum ejection stress values. The tablet strength was determined using the tensile strength method and tablet disintegration study was also conducted. The results showed that the increase in the compaction pressures increased the plastic work, maximum ejection pressure, tablet strength and also its disintegration time. The tablet formed having 95% w/w mannitol composition exhibited the highest plastic work value of 10.32±0.01 J, highest maximum ejection pressure value of 4.4±0.06 MPa, highest tensile strength value of 1.06±0.04 MPa and shortest disintegration time of 171±51 s amongst the three different mannitol compositions studied. Meanwhile, the effects of mannitol composition in the tablet on these observed responses were also dependent upon the compaction pressures used during tablet formation. In conclusion, the addition of mannitol improved the tablet strength and shorten the disintegration time in the experimental range employed in this study.