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

Abstract

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.

Semi-Solid Slurries for Rheocasting of Hypoeutectic Al-Si-X Alloys Produced by Self-Stirring in Serpentine Channels

“…The solid fraction f ∝(Al) was calculated by the Scheil model [29][30][31][32][33][34] according to the Equations ( 1) and (2) in terms of the process temperature (T), and the solute distribution coefficient between the solid and the liquid phases (k), where T m is the melting temperature of Al, T l is the liquidus temperature of the alloy, and T e is the eutectic temperature of the Al-Si system; the solute distribution coefficient for hypoeutectic Al-Si alloys is equal to 0.1309 just at the eutectic temperature. The boundary conditions for hypoeutectic Al-Si alloys are T e ≤ T ≤ T l for the process temperature and 0 ≤ X 0 ≤ 0.126 for the composition field, where X 0 is the alloy composition and X L is the solute content at T into the liquid.…”