1. MARCO REFERENCIAL
4.10 DESCRIPCIÓN DEL PROCESO PRODUCTIVO DE LA PAPA EN EL
As a newly developed PM process, DPF process exhibits some advantages over traditional HIPing process for manufacturing net-shape or near net-shape components, while significantly improves the efficiency by reducing the process time to only a few seconds and the microstructure by introducing more recrystallisation. On the other hand, there are a few aspects that need to be considered for industrial applications. Further investigations and modifications are suggested as follow:
1) Mechanical properties of a single FGH96 powder: in this research, the mechanical properties of fully dense FGH96 superalloy is used to approximate a single FGH96 powder. It is highly recommended to perform compression tests on a single powder at elevated temperatures to identify the different deformation behaviours between powder and fully dense material. This will also contribute to the development of the powder material model.
2) Complex shape components: all experiments conducted in this research are designed for a simple cylinder shape test-piece to study the powder
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compaction during DPF process. For further investigations, complex shape components, for example a ring component or an irregular polygon component, are proposed to be tested under both laboratory and industrial circumstances to investigate the powder consolidation condition in a more complicated stress-strain state.
3) Die and tool-set design: the applied forces in both experimental tests and FE simulations are parallel to the axis of the test-piece and in only one direction. When no constraint is applied to the rim, results show a relatively low powder density in the near rim locations of the test-piece. On the other hand, when constraint is applied, the powder consolidate is considerably improved. This needs to be taken into consideration for the design of the die and tool-set for DPF process.
4) Critical values for process parameters: it is believed that there exists a set of critical values for process parameters, i.e. temperature, loading force and holding time, to produce fully dense components. This will be of great importance to the design of DPF process and provide a valuable guidance to the industrial applications.
5) Softening mechanisms: the softening behaviour of FGH96 is modelled with a simplified damage equation in this research. Although a good agreement is achieved by the current model in the conditions investigated, it is recommended to modify the current empirical model to mechanism-based model by studying static/dynamic recovery and recrystallisation, which will further improve the accuracy of the material model and better describe the microstructure evolution.
6) Powder density evolution: the powder density evolution is currently predicted with Duva’s porous material model, which models the powder consolidation on a macro-scale level but could not explain the microstructural evolution within the powder material. A microstructural mechanism-based powder density evolution model should be developed for further implementation.
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