Experimental and theoretical modeling of induction sintering process of powder metal parts

In this study, induction of iron-based powder metal parts sintering process were investigated experimentally and theoretically. In the working used Högenas ASC 100.29 iron powder containing 3% Cu, 0.5% graphite and lubricant 0.8% Kenolube. Pre-heating, sintering time, the conveyor belt speed and gradually cooling, induction sintering and sintering parameters of the effects of macro-and micro size effects on mechanical properties of the samples were investigated experimentally and numerically. Powder materials micro-mechanical properties is very difficult to determine experimentally of depending on the inner porosity. Because of searching this features, photos of the internal structure of the samples using the method of image processing, obtained real microstructure images were numerical analyzed. The sintering parameters changes is greatly affected the micro and the macro mechanical properties. Obtained the results, in the industrial powder metal parts, induction sintering controlled by providing superior mechanical and physical properties was obtained of the internal structure. Induction is very difficult to control the heat of materials. In the study, adjustable medium-low (2.5-5 kHz) frequencies induction pre-heating process were tested. Besides, induction heating process, the heat generated in the samples scatter graphs were modeled numerically and tried to get the most accurate results with the experimental data transferred. Induction sintered samples, preheating with 5 Kw power, 300 Amp. current value, a low frequency (2.5 kHz), 600 °C and also, sintering process with 12 Kw power, 850 Amp. current value of medium frequency (45 kHz), 1120 ° C on the argon gas atmosphere, the samples by applying superior physical and mechanical properties and thermal shock has been blocked. PLS-controlled conveyor belt for optimum induction heating sintering conditions were developed. Speed of the conveyor belt can be controlled with a system that is designed for mass production. With the induction sintering sintering, dimensions of 10x10x55 mm specimen was found the most suitable sintering conveyor speed. The appropriate sintering parameters were obtained by experimental and numerical results. Keywords: Powder Metallurgy, Induction Sintering, Image Processing Analysis.