Finite element simulation of electromagnetic axial powder compaction of SS 316 powder

Electromagnetic axial powder compaction (EMAPC) uses strong magnetic fields to compact powder metallurgy components at high speeds. Lorentz forces accelerate the punch to compact powder in EMAPC. Thus, high magnetic fields cause powder deformations in microseconds. Therefore, measuring the compact height, magnetic field distribution, and compaction velocity was difficult. No literature has reported EMAPC finite element (FE) modeling. Thus, an LS-DYNA multi-physics solver-based FE 3D model has been developed to study SS316s EMAPC. A cylindrical SS316 sample was simulated for EMAPC at various discharge energies. The powder-compressed sample's final deformation was predicted through simulation. To characterize compacted samples, sintered samples were studied for density, porosity, and microhardness. Compressed samples were microscopically examined using optical microscopy. Increased discharge energy lowers height, increases density, and microhardness. FE analysis can be used to optimize EMAPC process parameters for powder compact density and porosity.