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Computerized Powder Metallurgy (P/M) Forging Techniques

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Final rept.

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Forging of sintered powder preforms is an attractive manufacturing alternative to conventional forging as it combines the cost and material saving advantages of conventional, press-and-sinter, powder metallurgy and the property enhancement of forging. The preforms contain a dispersion of voids, and forging of such materials into finished shapes must be accomplished such that no defects are formed and all residual porosity is eliminated. These objectives can be achieved through the proper design of the powder preform. The design currently is accomplished through a lengthy trial-and-error procedure. Empirical design rules have been established, from simplemodel experiments, to facilitate the proper design of preforms. Application of these rules to complex components requires an understanding of the behavior of porous materials with respect to densification, flow and fracture and the effects of die design, lubrication and temperature. An interactive computer-aided design approach was developed to facilitate the design and evaluation of preforms. The design was accomplished in two phases. The first phase described the part to be forged together with a schematic subdivision of the part into regions. The second phase involved the specification of trial preform shapes for the part. The program evaluated the input shape for densification and non-aggravating metal flow.

Subject Categories:

  • Metallurgy and Metallography
  • Fabrication Metallurgy

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