Electromagnetic Compaction and Radial Mechanical Pressing of Aluminium Powder

Abstract

Powder metallurgy is a versatile manufacturing process known for its ability to produce complex-shaped components with tailored properties, making it invaluable across multiple industries. This study investigates and compares the compaction behaviour, mechanical properties, and microstructure of pure aluminium powder using both conventional strain rate compaction, i.e. radial mechanical pressing (RMP) and high strain rate compaction, i.e. electromagnetic compaction (EMC) methods. The RMP process employs a hydraulic press to compact the powder conventionally. In contrast, in the EMC process, a rapid and intense magnetic field is generated through a solenoid coil, resulting in high-strain-rate compaction. Both process involves radial compaction of powder to generate a cylindrical specimen. After compaction, the samples are sintered, prepared, and tested. The testing includes hardness tests and microstructural analysis by using optical microscopy as well as scanning electron microscopy (SEM) imaging. Results are compared between the RMP and the EMC processes. This research aims to fill a critical gap in the field by enabling a direct comparison of radial compaction of powder at conventional and high strain rates, providing valuable insights into the influence of strain rate on the properties of powder compacted samples. © The Institution of Engineers (India) 2026.