A visco-plastic constitutive model for accurate densification and shape predictions in powder metallurgy hot isostatic pressing

TL;DR

This paper introduces a visco-plastic model for powder metallurgy hot isostatic pressing that improves prediction accuracy and requires less experimental data, enabling better understanding and control of the process for large-scale components.

Contribution

A novel visco-plastic model with a new calibration approach that matches plastic model data requirements and enhances prediction accuracy in PM-HIP simulations.

Findings

Visco-plastic model achieves similar results to plastic model with less data.

The model accurately predicts shape distortions in complex geometries.

Quantitative comparison shows advantages over traditional plastic models.

Abstract

Powder metallurgy hot isostatic pressing (PM-HIP) is an advanced manufacturing process that produces near net shape parts with high material utilization and uniform microstructures. Despite being used frequently to produce small-scale components, the application of PM-HIP to large-scale components is limited due to inadequate understanding of its complex mechanisms that cause unpredictable post-HIP shape distortions. A computational model can provide necessary information about the intermediate and final stages of the HIP process that can help understand it better and make accurate predictions. Generally, two types of computational models are employed for PM-HIP simulations, namely, plastic and visco-plastic models. Between these, the plastic model is preferred due to its cheaper calibration approach requiring less experimental data. However, the plastic model sometimes produces incorrect predictions when slight variations of the HIP conditions are encountered in practical situations. Therefore, this work presents a visco-plastic model that addresses these limitations of the plastic model. A novel modified calibration approach is employed for the visco-plastic model that utilizes less experimental data than existing approaches. With the new approach, the data requirement is same for both plastic and visco-plastic models. This also enables a quantitative comparison of plastic and visco-plastic models, which have been only qualitatively compared in the past. When calibrated with the same experimental data, both the models are found to produce similar results. The calibrated visco-plastic model is applied to several complex geometries, and the predictions are found to be in good agreement with experimental observations.