Finite element sintering analysis of metal injection molded copper brown body using thermo-physical data and kinetics

A finite element analysis based on a thermo-kinetic model was established to describe the densification process of a MIM copper brown body during sintering. This finite element analysis does not require a constitutive law; rather the thermo-physical data (density, thermal conductivity, specific heat as a function of temperature) and kinetics are used to predict sintering deformation. The thermo-physical data were obtained by measuring the brown MIM copper compacts using dilatometer (DIL), laser flash (LFA) and differential scanning calorimeter (DSC). These aspects are included in our work with emphasis on the development of a numerical model which is made possible by the commercial finite element software ANSYS@. To verify the densification-based finite element method, two case studies are made and discussed. The numerical predictions were compared with experimental measurements, and it is shown that the results numerically simulated by FE agree well with those experimentally observed by furnace sintering. Furthermore, some enhancements are suggested in temperature field calculation of FE model in order to draw a real furnace conditions.

► Thermo-kinetic analysis describes the densification process of a MIM copper.
► Finite element analysis does not require a constitutive law.
► The thermo-physical data were measured by thermoanalytical techniques.
► Thermal diffusivity followed by thermal conductivity was corrected using actual thickness of the specimen during the sintering process.
► FE results were compared to experimental results and showed satisfactory agreement.