Mesoscopic sinter simulation of sintered steelsCopyright: © IWM
The classical powder metallurgical process chain enables the cost-efficient production of highly precise components. Water-atomized powder-particles, that stand out by their highly irregular shape, are uniaxially compacted to so-called green bodies. The subsequent sintering process is a specific heat treatment, which activates diffusion processes and provokes the formation of sintering necks between single particles. Parameters such as temperature, holding time, and heating or cooling rate have an impact on the microstructural evolution as they directly influence the diffusion process. Any microstructural evolution caused by the sintering process will be reflected in the mechanical properties of the respective component. The simulation of this process enables the prediction of final properties based on the respective process design. Continuum mechanical approaches include the numerical description of the deformation caused by the heat treatment, whereas a mesoscopic simulation would offer detailed information concerning the diffusion-controlled behaviour of the microstructure. This provides precise knowledge of microstructural characteristics such as grain size, pore size and morphology as well as their distribution.
The project’s objective is the development of a digital twin of the sintering process, making diffusive processes accessible while providing information, that can be used for multiscale simulation, process chain simulation, and the prediction of properties of the final products.
Material characterisation: Determination and measurement of material properties that are necessary for a physical description of the sintering process
Method: Development of a method to numerically describe diffusive processes occurring during sintering on a mesoscale
Data base: Generation of synthetic micrographs based on given process conditions
Simulation: Numerical calculations of the microstructural evolution that depend on process parameters, while considering the initial microstructure of green bodies, using experimental data as well as synthetically generated micrographs
Validation: Comparison of predicted microstructures with experimental results
Grant number: EXC-2023 Internet of Production – 39062161