Metallic Powder Synthesized by Ultrasound-Assisted Electrical Discharge: Parametric Optimization-Based iSIGHT Platform and Feasible Micro-fabrication Sintering

The ultrasound-assisted electrical discharge is a low-cost and simple-operating method to prepare raw metallic powder for sintering micro-components. The powder size distribution plays a role in the sintering performance and the mechanical property of as-sintered components. Electrical parameters (current, voltage and pulse width) and ultrasonic power govern the size distribution of powder. Based on the iSIGHT platform, the orthogonal experiment is designed to investigate the main effect and interaction effect of four main parameters on the average particle size (D50). It was found that pulse width, current and ultrasonic power have a significant impact on reducing the D50 value. Then, a regression equation was built to achieve the prediction of the D50 value. The multi-physical field sintering method was used to realize the solidification of the as-synthesized metallic powder. When the sintering temperature was 900 & DEG;C, the nearly full-density (8.61 g/cm(3) relative density: 96.73%) micro-cylinder parts were obtained with a high bonding force and good compression resistance due to the mixture of micron and nano-size powder. Nano-sized powder first occurred in low-temperature sintering, and the combination of powder became denser with increasing sintering temperature.

Automated summary

Ultrasound-assisted electrical discharge is an affordable and easy method for preparing metallic powder for sintering micro-components. The size distribution of the powder affects the sintering performance and mechanical properties of the components. By conducting an orthogonal experiment, the study found that pulse width, current, and ultrasonic power significantly reduce the average particle size (D50). A regression equation was then developed to predict the D50 value. Through the multi-physical field sintering method, nearly full-density micro-cylinder parts with high bonding force and compression resistance were obtained at a sintering temperature of 900°C due to the combination of micron and nano-size powder.