Project Report Final

EVALUATION PROPERTIES OF
ALUMINIUM - POLYAMIDE (ALUMIDE)

SINTERED PRODUCT
A project report submitted in partial fulfillment of the requirement for the award of the degree of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
By
ASIF BAIG Regd. No. 1210814404
B. YESWANTH REDDY Regd. No. 1210814407
CH. SRIKRISHNA SAI Regd. No. 1210814411
SRI HARSHA THURPU Regd. No. 1210814456
PAPPALA VEERENDRA Regd. No. 1210814460
Under the esteemed guidance of
Shri BH. LAKSHMIPATHI. RAJU

Assistant Professor
DEPARTMENT OF MECHANICAL ENGINEERING,

GITAM INSTITUTE OF TECHNOLOGY, GITAM (Deemed to be University),
RUSHIKONDA, VISAKHAPATNAM,
ANDHRA PRADESH-530045.
INDIA
2014-2018
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DEPARTMENT OF MECHANICAL ENGINEERING
GITAM INSTITUTE OF TECHNOLOGY, GITAM
Rushikonda, Visakhapatnam-530045.
CERTIFICATE
This is to certify that the project entitled “Evaluation properties of Aluminium

- Polyamide (Alumide) Sintered product” submitted to the GITAM (Deemed to
be University), Visakhapatnam, India for the award of the degree of Bachelor
of Technology in Mechanical Engineering is a bonafide record of project
work carried out by them under my supervision. The contents of the Project
Report, is full or in parts, have not been submitted to any other institute or
university for the award of any degree or diploma.
Shri BH. LAKSHMIPATHI. RAJU Prof. Dr. M. R. S. SATYANARAYANA

(PROJECT GUIDE) (HEAD OF THE DEPARTMENT)
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DECLARATION
We, hereby declare the project entitled “EVALUATION PROPERTIES OF

ALUMINIUM - POLYAMIDE (ALUMIDE) SINTERED PRODUCT”
submitted by us to the Department of Mechanical Engineering, Gandhi Institute of
Technology, GITAM, Visakhapatnam, India for the award of the degree of
Bachelor of Technology in Mechanical Engineering is a record of project work
carried out by us. This work has not been submitted to any other university or
institution for the award of any degree.
By-
Station: Visakhapatnam
Date:
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ACKNOWLEDGEMENTS
This is an acknowledgement of the intensive drive and technical competence of many individuals
who have contributed to the success of our project “EVALUATION PROPERTIES OF
ALUMINIUM - POLYAMIDE (ALUMIDE) SINTERED PRODUCT”.
The satisfaction and euphoria that accompany the successful completion of our project would be
bit incomplete without the mention of the people who made it possible, where constant guidance
and encouragement crown all the effort with success.
We consider it a privilege to express our gratitude and respect to Dr. M. R. S. Satyanarayana,

Head of the Department, Mechanical Engineering for his valuable teachings, suggestions and
support which led to successful completion of this project.
We express our deep sense of gratitude to our guide Shri Bh. Lakshmipathi Raju, Assistant
Professor, Department of Mechanical Engineering for creating good opportunity to expose
our talents and shape us through his valuable guidance, unstinting support, administration,
suggestions and piece of advice in all respects and continuous encouragement which led to
successful completion of project.
We consider it a privilege to express our gratitude and respect to Dr. Pujari Srinivasa Rao,
Assistant Professor, and Mechanical Engineering for his valuable teachings, suggestions,
support, guidance and continuous encouragement which led to successful completion of this
project.
We are also thankful to the technical staff of machine shop for helping us carry out our
experimentation. We express our thanks to all the teaching and non-teaching staff members of
the department of Mechanical Engineering for their direct or indirect support to carry out this
project work.

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Abstract
Alumide, which is a blend of aluminium and polyamide powder, makes the components
lustrous and nonporous and is manufactured by methods like rapid prototyping, powder
metallurgy where fine powder of Aluminium is mixed with the polyamide powder in microns. In
powder metallurgy, the metal powder is compacted in a die through the application of high
pressures by Die pressing method. Typically, the tools are held in the vertical orientation with
the punch tool at the bottom of the forms a cavity. The powder is then compacted into a shape
and then ejected from the die cavity, the throughput is processed through Hydraulic pressing.
The compacted metal powder is taken in an oven under a high temperature for a long period of
time using the Sintering process where the porous aggregate particles bind together under heat
and solidify once it is gradually cooled. The characteristics of Polyamide fiber that they are
tough, highly tensile, lustrous as well as elastic in nature due to which it will enhance the
properties of aluminum. Furthermore, they are highly resistant to abrasion and chemicals such as
acids and alkalis. Though Alumide have the hardness and thermal conductivity close to
Aluminium which is known for its toughness, hardness and is commonly used as frames in the
quadcopter, mobile cases, they can be used as a good replacement for Aluminium as they are
light in weight. The Polyamide which binds the aluminum will ensure that properties of
aluminum not get disturbed and help in incremental behavior of few characteristics which are
used in heavy duty applications.
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CONTENTS
PROJECT TITLE i
CERTIFICATE ii
DECLARATION iii
ACKNOWLEDGEMENTS iv
ABSTRACT v
1 INTRODUCTION 1
1.1 Alumide 1
1.2 Powder Metallurgy 1
1.3 Powder Compaction 2
1.4 Die Pressing 3
1.5 Sintering 3
1.6 Properties and applications of Aluminium 4
1.7 Properties and applications of PA6, 6 5
1.8 Properties and applications of PA6 8
2 LITERATURE REVIEW 10
2.1 Application oriented troubles with aluminum 10

2.2 Compaction study 10
2.3 Spring back gradient 12
2.4 Consolidation Mechanism 13
2.5 Future Advances 14
2.6 Summary 16
3 EXPERIMENTATION 17
3.1 Materials Used 17

3.2 Weight Compositions of Powders 17
3.3 Blending Process 18
3.4 Compaction 19
Experimental Setup 19
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Experimental Procedure 20
3.5 Sintering 22
Muffle Furnace 22
Sintering Procedure 23
Sintering Cycles 24
3.6 Microstructure of Various Compositions 33
3.7 Testing of Samples 34
Hardness Test 34
Compression Test 35
Moisture Absorption Test 37
NDT 37
Density Analysis 38
4 RESULTS AND DISCUSSION 40
4.1 Compaction Curves 40

4.2 Comparison of Hardness 46
4.3 Variation of Moisture Absorption 48
4.4 Compression Curves 50
4.5 Density Analysis 58
5 CONCLUSION 59
6 REFERENCES 61
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LIST OF FIGURES, TABLES AND GRAPHS
LIST OF FIGURES: PAGE NO.
• Figure 1 – Literature review sample graphs 11

• Figure 2 – Relaxation assist device 13
• Figure 3 –Selective Laser Sintering 15
• Figure 4 – Aluminium powder 17
• Figure 5 – Polyamide 6 powder 17
• Figure 6 – Polyamide 6,6 powder 17
• Figure 7 – Hand mixing of two powders 18
• Figure 8 – Compaction experimental set up 19
• Figure 9 – Die and punch 19
• Figure 10 – Punch & Die system during compaction 21
• Figure 11 – Green Briquette 21
• Figure 12 – Muffle furnace 22
• Figure 13-15 – Microstructures of some samples 33
• Figure 16 – Polishing of samples 34
• Figure 17 – Fatigue testing machine 36
• Figure 18-19 – Sample before and after compression 36
• Figure 20 – NDT Set up 38
• Figure 21 – Measuring flask for density analysis 38
LIST OF TABLES:
• Table 1 – Weight Composition of powders 17

• Table 2 – Observational readings of compaction parameters 20
• Table 3 – Readings for Vickers hardness test 35
• Table 4 – NDT Quality analysis readings 37
• Table 5 – Readings for density measurement 39
• Table 6 – Calculation of Compaction parameters 41
• Table 7 – Vickers hardness comparison 46
• Table 8 – Observation for Moisture absorption 48
• Table 9 – Percentage moisture absorption results 49
• Table 10-17 – Result analysis of compression test 50
• Table 18 – Relative density and porosity Calculations 58
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LIST OF GRAPHS:
• Graph 1-9 – Sintering cycles for various compositions 24

• Graph 10 – Compacting Time variation of different compositions 41
• Graph 11 – Variation of compaction energy 42
• Graph 12 – Strain rate variation 43
• Graph 13-16 – Punch displacement at different instances 44
• Graph 17 – Hardness Variation of samples 47
• Graph 18 – Variation in moisture absorption 49
• Graph 19-26 – Compression curves of samples 50
• Graph 27—Porosity Variation 58
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INTRODUCTION
1.1 ALUMIDE
Alumide is a material consisting of nylon filled with aluminum dust, its name being a
combination of the words aluminium and polyamide. Models are printed by sintering the
compacted powder in sintering furnace. While it is much stiffer than other materials used in 3D
printing, it can also withstand much higher thermal loads, maintaining its shape at temperatures
that would cause thermoplastic compounds such as polylactic acid to become molten.
1.2 POWDER METALLURGY
Powder metallurgy (PM) is a term covering a wide range of ways in which materials or
components are made from metal powders. PM processes can avoid, or greatly reduce, the need
to use metal removal processes, thereby drastically reducing yield losses in manufacture and
often resulting in lower costs.
Powder metallurgy is also used to make unique materials impossible to get from melting or
forming in other ways. Products include sintered filters, porous oil-impregnated bearings,
electrical contacts and diamond tools.
Since the advent of industrial production–squale metal powder–based additive manufacturing
(AM) in the 2010s, selective laser sintering and other metal AM processes are a new category of
commercially important powder metallurgy applications.
The history of powder metallurgy and the art of metal and ceramic sintering are intimately
related to each other. Sintering involves the production of a hard solid metal or ceramic piece
from a starting powder.
In powder metallurgy or ceramics it is possible to fabricate components which otherwise would
decompose or disintegrate. All considerations of solid-liquid phase changes can be ignored, so
powder processes are more flexible than casting, extrusion, or forging techniques. Controllable
characteristics of products prepared using various powder technologies include mechanical,
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magnetic and other unconventional properties of such materials as porous solids, aggregates, and
inter-metallic compounds.
Any fusible material can be atomized. Several techniques have been developed which permit
large production rates of powdered particles, often with considerable control over the size ranges
of the final grain population. Powders may be prepared by crushing, grinding, chemical
reactions, or electrolytic deposition.
1.3 POWDER COMPACTION
Powder compaction is the process of compacting metal powder in a die through the
application of high pressures. Typically the tools are held in the vertical orientation with the
punch tool forming the bottom of the cavity. The powder is then compacted into a shape and then
ejected from the die cavity.[9] In a number of these applications the parts may require very little
additional work for their intended use; making for very cost efficient manufacturing.
The density of the compacted powder increases with the amount of pressure applied. Typical
pressures range from 80 psi to 1000 psi (0.5 MPa to 7 MPa), pressures from 1000 psi to
1,000,000 psi have been obtained. Pressure of 10 tons/in² to 50 tons/in² (150 MPa to 700 MPa)
are commonly used for metal powder compaction. To attain the same compression ratio across a
component with more than one level or height, it is necessary to work with multiple lower
punches. A cylindrical work piece is made by single-level tooling. A more complex shape can be
made by the common multiple-level tooling.
Production rates of 15 to 30 parts per minute are common.
There are four major classes of tool styles: single-action compaction, used for thin, flat
components; opposed double-action with two punch motions, which accommodates thicker
components; double-action with floating die; and double action withdrawal die. Double action
classes give much better density distribution than single action. Tooling must be designed so that
it will withstand the extreme pressure without deforming or bending. Tools must be made from
materials that are polished and wear-resistant.
Better work piece materials can be obtained by repressing and re-sintering.
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1.4 DIE PRESSING
The dominant technology for the forming of products from powder materials, in terms of
both tonnage quantities and numbers of parts produced, is die pressing. There are mechanical,
servo-electrical and hydraulic presses available in the market, whereby the biggest powder
throughput is processed by hydraulic presses. This forming technology involves a production
cycle comprising:
1 Filling a die cavity with a known volume of the powder feedstock, delivered from a fill
shoe.
2 Compaction of the powder within the die with punches to form the compact. Generally,
compaction pressure is applied through punches from both ends of the toolset in order to
reduce the level of density gradient within the compact.
3 Ejection of the compact from the die, using the lower punch (es) withdrawal from the die.
4 Removal of the compact from the upper face of the die using the fill shoe in the fill stage
of the next cycle, or an automation system or robot.
This cycle offers a readily automated and high production rate process.
1.5 SINTERING
Solid state sintering is the process of taking metal in the form of a powder and placing it
into a mold or die. Once compacted into the mold the material is placed under a high heat for a
long period of time. Under heat, bonding takes place between the porous aggregate particles and
once cooled the powder has bonded to form a solid piece.
To allow efficient stacking of product in the furnace during sintering and prevent parts sticking
together, many manufacturers separate ware using ceramic powder separator sheets. These sheets
are available in various materials such as alumina, zirconia, and magnesia. They are also
available in fine, medium, and coarse particle sizes. By matching the material and particle size to
the wares being sintered, surface damage and contamination can be reduced, while maximizing
furnace loading per batch.
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1.6 ALUMINIUM PROPERTIES AND APPLICATIONS:
Within the family of metals only silver, copper and gold have better electrical
conductivity. Also the thermal conductivity of aluminium is very high, while its melting point is
just above 660°C.
Anodized aluminium has an even higher corrosion protection than the untreated raw material as a
result of its special surface. In addition, aluminium is corrosion-proof in the neutral pH range due
to its oxide layer. Rust does not adhere to this top layer since the light alloy is itself protected by
this sealing layer.
Furthermore, no iron contents are present in aluminium. This has as result that it is not magnet
sable or is only paramagnetic, which means that it has no external magnetic characteristics. An
important property and difference in comparison with steel and iron.
Its further characteristics:
• Low density
• Simple to process
• Smooth surface
• Lower dimensional tolerances
• Not magnet sable
• Can be decoratively anodized very well (dependent on the alloy)
• Suitable for use in the food sector (EN 602)
• Good machinability (dependent on the strength and alloying elements)
Areas of application:
Aluminum can be used for many purposes and is therefore a particularly good selection for DIY
craftsmen. Often consumers decide between wood and metal, for example in case of carports,
garden houses or balcony balustrades.
The advantage compared to wood in the outdoor area is the weathering protection: unlike wood,
you do not need to paint the metal regularly.
Also in the house aluminium profile sections have uses, among other things, as carpet edge
protection, furniture elements or for LED installations. Here in particular the optics plays a large
role.
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Aluminium surfaces can be very varied.
The material is also often used for modern items of jewelry. In comparison with steel, a simple
further processing of the material is possible.
Further areas of application:
• Roof elements
• Electrical engineering
• Preserving tins
• Boats and particularly yachts
• As a powder form in fireworks
Natural Abundance:
Aluminium is the most abundant metal in the Earth’s crust (8.1%) but is rarely found
uncombined in nature. It is usually found in minerals such as bauxite and cry lite. These minerals
are aluminium silicates.
Most commercially produced aluminium is extracted by the Hall–Herald process. In this process
aluminium oxide is dissolved in molten cry lite and then electrolytic ally reduced to pure
aluminium. Making aluminium is very energy intensive. 5% of the electricity generated in the
USA is used in aluminium production. However, once it has been made it does not readily
corrode and can be easily recycled.
1.7 PROPERTIES AND APPLICATIONS OF PA6:
Properties:
Nylon 6 fibers are tough, possessing high tensile strength, as well as elasticity and luster. They
are wrinkle-proof and highly resistant to abrasion and chemicals such as acids and alkalis. The
fibers can absorb up to 2.4% of water, although this lowers tensile strength. The glass transition
temperature of Nylon 6 is 47 °C.
5
As a synthetic fiber, Nylon 6 is generally white but can be dyed to in a solution bath prior to
production for different color results. Its tenacity is between 6 and 8.5 gm/den with a density of
1.14 gm/cc. Its melting point is at 215 °C and can protect heat up to 150 °C on average.
Applications:
Main Applications of polyamide 6 includes:

• Automotive
• Electrical
• Fibers / Textiles
Automotive Applications:
Polyamide 6 is very often used to replace metal in automotive parts where design flexibility as
well as temperature and chemical resistance are critical. Polyamide 6 applications in automotive
comprise of manufacturing door handles, radiator grilles, airbag containers, air-intake manifolds,
relay boxes, engine covers etc.
Related key features that make PA6/ Nylon 6 ideal for automotive applications include:
• Excellent surface appearance
• Good paint ability, U.V resistance and mechanical properties, like stiffness and toughness
• Exceptional chemical and heat resistance
• Outperforming toughness and fatigue resistant
• Excellent flow characteristics
• Short injection cycle times
• Excellent weld line strength at elevated temperatures
• Practical dimensional accuracy
• Low warpage
• Good surface finish
• Easy and speedy process-ability
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Electrical Applications:
Polyamide 6 applications in electrical market mainly include manufacturing low voltage switch
gears, circuit breakers, contactors, connectors, tubes for wirings and cables protection and much
more for the electronics market.
Related key features that make PA6/ Nylon 6 ideal for such applications include:
• Good electrical insulating properties
• Good process-ability, allow thin walls.
• Laser marking ability
• Low flammability, using halogen free flame retardants
• Practical ball pressure temperature
• High stiffness and toughness
• High heat distortion temperature
• Excellent flow characteristics
• Short injection cycle time
• Weight less compared to metal tubes
Fibers/Textiles/Carpets Applications:
PA6 is also used in the fibers/textiles/carpets market to produce carpets and rugs, bristles,
brushes, brooms etc.
Related key features that make Polyamide 6 ideal for such applications include:
• Superior appearance retention due to outstanding resilience.
• Exceptionally resistant to dirt, wear, chemicals, crushing and matting.
• Easy to clean.
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1.8 PROPERTIES AND APPLICATIONS OF PA6:
PA66, Nylons are tough, ridged, have high tensile strength and good resistance to creep,
excellent abrasion, chemical and heat resistance and a low coefficient friction.
Physical Properties Metric

Density 1.14 g/cc
Water Absorption 1.2%
Mechanical Properties Metric

Hardness, Rockwell M 90
Tensile Strength, Yield 80.0 MPa
Elongation at Break 25%
Tensile Modulus 2.41 GPa
Flexural Strength 107 MPa
Compressive Strength 34.5 MPa
Izod Impact, Notched 0.587 J/cm
Coefficient of Friction, Dynamic 0.26
K (wear) Factor 403 x 10-8 mm³/N-M
Electrical Properties Metric

Volume Resistivity 1.00e+15 ohm-cm
Thermal Properties Metric
Specific Heat Capacity 1.67 J/g-°C
Melting Point 255 °C
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Applications :
PA66 Applications in Automotive/Transportation

Polyamide 66/ Nylon 66/ PA66 is very often used to manufacture door handles, radiator grilles,
airbag containers, air-intake manifolds, relay boxes, engine covers etc. for the automotive
industry.
1 Excellent surface appearance
2 Good paint ability
3 Good U.V resistance and mechanical properties like stiffness and toughness
4 High heat resistance
5 Good chemical resistance
6 Outperforming toughness and fatigue resistance
7 Excellent flow characteristics
8 Short injection cycle times
9 Superior weld line strength at elevated temperatures
10 Low warpage
11 Good surface finish
12 Easy and speedy process-ability.
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LITERATURE REVIEW
2.1 APPLICATION ORIENTED TROUBLES WITH

ALUMINIUM
Generally Aluminium has wide range of applications like aircraft inner layer for which weight
reduction is the key factor and to maintain its hardness & Toughness properties. By adding
polyamide 6 and polyamide 6,6 weight reduction will take place by not leading to much variation
in moisture absorption as well.
Another crucial application of aluminium are drone frames for also moisture, weight reduction
and toughness plays an important role.
2.2 COMPACTION STUDY

Bruska Azhdar proposed a method for compaction of polyamide powders by high velocity cold
compaction method and also discussed various compaction parameters
The below mentioned details indicates the compatibility characteristics and the research paper
details are as follows:
AKADEMISK AVHANDLING
Som med tillstånd av Kungliga Tekniska Högskolan i Stockholm framlägges till offentlig
granskning för avläggande av teknisk licentiatexamen onsdag den 21 September 2005, kl. 10.15 i
sal B1, Brinellvägen 23, KTH, Stockholm. Avhandlingen försvaras på svenska.
o Compacting by a single stroke, P post-down, of polyamide is insufficient to achieve an
adequate density. One stroke occurs under a relatively short time, and this is not
sufficient to reorganize and deform the particles both elastically and plastically.
o As the pre-compaction energy increases the compacting time decreases, and the particles-
particularly the coarse particles- have less time to move and slide past each other. As a
result, the porosity between powder particles increases and finally the apparent density
decreases.
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Changing the pressure direction leads to evenness, homogeneity, and densification on the
surfaces as well as the density distribution in the compacted powder bed.
Figure 1: The relative green density plotted against compaction energy of a two-grade compacted PA11
(different particle size distributions) by: (a) One downward post compacting, P post-down profile, (b) A single
downward pre-compacting stroke followed by one constant downward post-compacting (300 J/g), Ppre + Ppost-
down profile.
Punch Movement terminology:

The compacted samples were prepared using three different post compacting profiles in order to
study the compression characterizations:
➢ Samples were compacted by a single downward pre compacting stroke, followed by a
single constant downward post compacting stroke.
This compacting profile is referred to as Pre + Post down.
➢ Samples were compacted by a single downward pre compacting stroke, followed by one
constant primary downward and one constant secondary upward post compacting stroke.
This compacting profile is referred to as Pre +Post down +Post up.
➢ Samples were compacted by a single downward pre compacting stroke, followed by one
constant primary upward and one constant secondary downward post compacting stroke.
This compacting profile is referred to as Pre + Post up +Post down.
The average strain rate in each case was calculated by dividing the compaction velocity by the
initial height of the powder bed.
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The compacting energy (energy per mass) in each case was calculated by dividing the total
energy transferred via the piston by the weight of the powder bed.
In the above literature of compaction of polymer & metal powders are described which will lead
to understanding the compaction related parameters. The density variation takes place.
The above-mentioned details are calculational formulas for processing the experiment and
introduced by Bruska Azhdar
2.3 SPRING BACK GRADIENT
As the polyamide content increases in the mixture of Alumide release of stress after ejection of
specimen from the die which is known to be as spring back effect.
During the compaction process, the powder undergoes a high compressive strain which
ultimately leads to consolidation and densification of the material. The process can be divided
into two stages, compacting and de compacting stages. In the compacting stage, the material is
compressed and the density of the material increases to the maximum value. After the max
pressure is reached and piston starts to withdraw, the compressive stresses relax and the material
expands due to elastic energy stored in the material. During this spring back stage, the density
decreases. Most of the spring back phenomenon occurs during decompaction stage, within the
die, rather than after ejection.
To overcome this problem, high velocity cold compaction and relaxation assist device is used.
Simple abstract is given below:
A uniaxial high-velocity compaction process for polymer powder using a cylindrical, hardened
steel die and a new technique with relaxation assist was tested with various heights. The
influences of the relaxation assist device on the process characteristics are discussed. Two
bonded strain gauges and a high-speed video camera system were used to investigate the spring
back phenomenon during the compaction process. It was found that the relaxation assist
improves the compaction of the polymer powder by locking the powder bed in the compacted
form. It is shown that the high-velocity compaction process is an interruption process and that
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the delay times between the pressure waves can be reduced by increasing the height of the
relaxation assist device. The delay times between the pressure waves are also strongly dependent
on the strain rate. If the height of the relaxation assist device is increased, the first gross
instantaneous spring back, and the total elastic spring back, are reduced. In addition, the density
of the powder bed is increased. The relative times of the compacting stage, decompaction stage
and the reorganization of the particles can be also controlled by altering the height of the
relaxation assist
Figure 2: Relaxation Assist
To improve the compaction process, a relaxation assist device has been developed. The
relaxation assists are parts of the piston and they are regarded as projectile supports. They are
constructed of the same material as the piston, and the diameters are the same but the lengths are
different, as shown in Fig. 1. The function of the relaxation assist device is to lock the powder
bed in the compacted form during the compaction process.
It is possible to increase the kinetic energy by increasing the hydraulic force or by increasing the
distance between the hammer and the top surface of the piston. It is difficult to increase the
hydraulic force without changing the design and/or initial parameters of the machine.
2.4 CONSOLIDATION MECHANISM
Generally, this method of solid state sintering and consolidation of particles depends upon
temperature, especially polyamide powders which was written by
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Problems in consolidation
There are two main general problems in consolidation:
➢ One, applicable to all process variants other than the full melting of metals, stems from
the short material heating times caused by the scanning laser beam, relative to the time
required for consolidation,
➢ The other problem, important for the full melting of metals, is quite the opposite. Here
the viscosity 􀁋 is about 1 to 5mPas [16], the surface tension 􀁋 about 1 to 2 N/m [12] and
consequently 􀁋/􀁋 􀁋 100 to 1000 m/s.
In literature there is no agreement on the nomenclature of the physical state of parts after laser
powder processing. Laser consolidation of polymers normally involves melting of
thermoplastics (partial-SLS or full-SLM).
A clear distinction should be made between :
o (semi-)crystalline thermoplastics
o Amorphous thermoplastics.
When heated up from very low to very high temperatures, all those thermoplastic materials will
change from a hard (solid and glassy) structure to a softer (tough leathery or rubbery, solid or
non-pourable) structure and finally turn into a viscous flowing melt. Materials however differ in
the way and the temperatures at which those transitions occur.
2.5 FUTURE ADVANCES

Our project on the material Alumide is made by normal compact sintering process in which the
mixture of aluminium and polyamide is compacted in a cylindrical die and heat the green
briquette in the muffle furnace. By this process we faced few problems that will make severe
impact on the properties of the material.
Some problems were listed below:
(i) Spring back effect of polyamide
(ii) Lack of proper channelized adhering
(iii) Lack of surface finish
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All the above problems can be overcomed by Additive manufacturing technique called SLS
(Selective Laser Sintering) in which Layer by Layer making will happen due to which strength &
toughness will also increase when compared to the compact sintering. When the powder is fed in
the machine then Laser will strike the polyamide particles and sintered above its melting point.
But, Due to aluminium particles have higher density and the energy density wouldn’t be
sufficient to create a model on this machine. Will lead damage the laser in the case of Polyamide
SLS or if we try this SLM then it will lead to vaporisation of polyamide due to very high energy
density.
This Material was first introduced by EOS Manufacturing company. But these materials was in
use for jewellery applications only, Research is still being processed in order to increase its
properties like hardness, strength, toughness, etc. For proceeding this material on the SLS the
hardware changes need to be done in order to balance energy densities of laser for Al and PA.
Figure 3
So, In future Selective laser sintering will play crucial role in moulding this material for complex
parts with better surface finish and mechanical properties.
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2.6 SUMMARY
In the above review it’s been mentioned regarding the material called Alumide and why we
adopted for production of this material. Also discussed about various compaction parameters and
results from the latest research papers.
Enhanced idea on the compaction of polymers and remedy that need to be adopted .These
applications on which Alumide can worth exhibits its properties by replacing the aluminium and
polyamide.
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EXPERIMENTATION
3.1 MATERIALS USED

o Aluminium Powder
Percentage purity: 99.5%
Average Grain size: 60 µm
Average density: 2.7 gram/cc
Figure 4
o Polyamide-6 Powder
Average grain size: 40 µm

Figure 5
o Polyamide-6,6 Powder
Average grain size: 40 µm

Figure 6
3.2 WEIGHT COMPOSITIONS OF POWDERS

Table 1:
Percentage Powder Composition (in %age) Powder Composition by weight (g)
Sr. No
Al PA-6 PA-66 Al PA-6 PA-66
1 100 - - 200 - -
2 90 10 - 180 20 -
3 90 10 180 - 20
4 80 20 160 40 -
5 80 20 160 - 40
6 80 10 10 160 20 20
7 70 30 140 60 -
8 70 30 140 - 60
9 50 50 100 100 -
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3.3 BLENDING PROCESS
Blending is the process of mixing of two or more powders in required proportions. In order to
obtain homogeneity of powders the blending process must be chosen well. There are various
methods to obtain homogeneous mixture of powders such as ball mills, ultrasonic mixing,
magnetic blending etc. In this project centrifugal mechanism has been utilized to blend the
powders.
Procedure:
o The weight composition of powder is taken and poured into mixer jar.
o It is made sure that the lid of the jar tightly fits the jar.
o The mixer grinder is then switched ON.
o Periodic increment of rotor speed is provided.
o The apparatus is operated for about 2 to 3 minutes and switched OFF.
o The lid is opened and the jar is emptied in a vessel.
o The homogeneity of powder obtained through this process is around 75%.
Figure 7
F = m r ω2
According to this formula, the grinding centrifugal force has been calculated.
Provided, the mass of the powder, radius of the jar and the angular velocity of the grinding
blades are known.
18
3.4 COMPACTION
Experimental Setup:
The compaction of the powder is done in a die using the compaction machine.
The machine which was utilized to compact the powders here is Compression Testing Machine
(CTM).
Compression Testing Machine consists of a robust base, with adjustable height.
It consists of a fixed head on the top. The load is given from the bottom side of the machine.
The sample to be tested is placed on the base with its above surface close to the top fixed head.
When the load is supplied to the machine, the base plate rises up to compact the sample.
It consists of pressure gauges mounted above the top plate. The values of compression are
thereby displayed on the load meter provided on top of the machine. The pressure control valve
and the operating switches of this machine are provided separately on another component which
is placed beside the machine.
In order to ensure safety there is door provided on this machine.
Figure 8 Figure 9
19
Experimental Procedure:
➢ The weight of powder to be compacted is first measured and poured into the die.
➢ Then the punch is inserted into the die and pressed over a flat surface using gentle manual
pressure.
➢ The die is then placed over the base of the compression testing machine.
➢ It has to be ensured that the top surface of the punch is close to the op fixed plate.
➢ It must also be ensured that the die is aligned properly with the setup.
➢ The compression testing machine is then switched on and the door is closed.
➢ After reaching the required load (i.e. 80kN) the machine is switched OFF and the load is
released.
➢ Now the base is lowered and the die is removed carefully.
➢ Now the support is placed on the base and the die is placed on the support.
➢ Load is again applied on the punch gradually, so that the green briquette falls inside the
support on the cotton by which the density variation takes place.
➢ The sample is carefully removed and processed for sintering, which is the next step in
production
The following table describes the details of experimental load and stress:
Table 2:
Powder Composition
Sr. No Powder Mass (grams) Initial Height (mm) Compacted Height(mm) Load (kN) Time (Sec) Stress (Mpa)
Al PA-6 PA-66
1 100 - - 6 21 12.8 50 19.1 282.9421211
2 90 10 - 4 25 16 50 17.3 282.9421211
3 90 10 3.5 26.5 16 50 16.9 282.9421211
4 80 20 3.7 27 16.8 50 15.1 282.9421211
5 80 20 3.2 28 14.4 50 14.5 282.9421211
6 80 10 10 3.8 31 15 50 15.5 282.9421211
7 70 30 3 32.4 17.9 50 13.8 282.9421211
8 70 30 2.9 33.1 16.2 50 14.2 282.9421211
9 50 50 2.6 35 20 50 12 282.9421211
20
Figure 10
Figure 11
21
3.5 SINTERING
Sintering is the process of compacting and forming a solid mass of material by heat or pressure
without melting it to the point of liquefaction.
The method adopted for this process is Solid State Sintering and it has been performed using the
Muffle Furnace.
Muffle Furnace:
A muffle furnace (sometimes retort furnace in historical usage) is a furnace in which the subject
material is isolated from the fuel and all of the products of combustion, including gases and
flying ash. After the development of high-temperature electric heating elements and widespread
electrification in developed countries, new muffle furnaces quickly moved to electric designs.
Figure 12
Maximum operating temperature: 1000 °C

Components:
Heating Coil
Digital Temperature Indicator
Temperature Regulating Valve
Heater ON/OFF Switch
22
Sintering Procedure:
In order to ensure the perfect sintering of the material, a sophisticated sintering cycle needs to be
implemented. The following lines clearly indicate the procedure to be followed to achieve a
perfect sinter cycle.
➢ The green briquette which is obtained from the compaction process is taken into a crucible.
➢ This crucible is carefully placed in the muffle furnace.
➢ The temperature of the furnace is set to 50 °C and the heater is switched ON.
➢ The stopwatch is simultaneously switched ON.
➢ As soon as the temperature reaches 50 °C the heater goes OFF and the time taken is noted.
➢ Now the temperature is kept constant for about 5 minutes and then the heater is turned ON.
➢ The above steps are carried by increment of temperature values of 150 °C, 250 °C and 350
°C.
➢ The time taken to attain these temperature are simultaneously noted down in a graphical
format.
➢ After the desired temperature is attained, the sample is now allowed to cool down gradually.
➢ The typical cooling period of a particular sample was found to be 56 minutes.
➢ It has been studied that the Cooling period majorly depends on the heat dissipating
characteristic of a material.
23
Sintering cycles:
Aluminium
600
500
400
Temperature (℃)
300
Actual Temp(°C)
Deviated Temp(°C)
200
100
0
0 500 1000 1500 2000 2500 3000 3500 4000
Time (Sec)
Graph 1
Time(Sec) Actual Temp(°C) Deviated Temp(°C)
0 27 27
518 100 100
698 100 140
1118 200 200
1254 200 225
1729 300 300
2029 300 330
2389 350 350
2689 350 375
3017 450 450
3377 450 478
24
Al-90% & PA 6-10%
400
350
300
Temperature (℃)
250
200
Actual Temp(°C)
150 Deviated Temp(°C)
100
50
0
0 500 1000 1500 2000 2500 3000
Time (Sec)
Graph 2
0 22 22
388 50 50
748 50 60
1138 150 150
1438 150 180
2158 300 300
2458 300 340
25
Al-90% & PA6,6-10%
400
350
300
Temperature (℃)
250
200
Actual Temp(°C)
Deviated Temp(°C)
150
100
50
0
0 500 1000 1500 2000 2500 3000
Time (Sec)
Graph 3
0 24 24
340 50 50
718 50 58
1108 150 150
1397 150 176
2122 300 300
2405 300 336
26
Al-80% & PA6-20%
350
300
250
Temperature (℃)
200
Actual Temp(°C)
150
Deviated Temp(°C)
100
50
0
0 500 1000 1500 2000 2500
Time (Sec)
Graph 4
Actual
Time(Sec) Deviated Temp(°C)
Temp(°C)
0 25 25
720 100 100
900 100 120
1162 150 150
1342 150 180
1787 250 250
1967 250 289
2120 300 300
2300 300 324
27
Al-80% & PA66-20%
350
300
250
Temperature (℃)
200
Actual Temp(°C)
150
Deviated Temp(°C)
100
50
0
0 200 400 600 800 1000 1200 1400 1600 1800
Time (Sec)
Graph 5
Actual Deviated
Time(Sec)
Temp(°C) Temp(°C)
0 50 50
240 50 80
491 100 100
701 100 110
864 158 158
1164 158 177
1344 300 300
1644 300 324
28
Al-80% PA6-10% & PA66-10%
350
300
250
Temperature (℃)
200
Actual Temp(°C)
150
Deviated Temp(°C)
100
50
0
0 500 1000 1500 2000 2500
Time (Sec)
Graph 6
0 25 25
720 100 100
900 100 120
1170 150 150
1349 150 180
1790 250 250
1970 250 289
2129 300 300
2300 300 324
29
Al-70% & PA6-30%
400
350
300
Temperature (℃)
250
200
Actual Temp(°C)
100
50
0
0 500 1000 1500 2000 2500 3000
Time (Sec)
Graph 7
0 25 25
400 50 50
640 50 91
1058 150 150
1298 150 185
1739 250 250
1979 250 278
2501 350 350
2801 350 380
30
Al-70% & PA66-30%
400
350
300
Temperature (℃)
250
200
Actual Temp(°C)
100
50
0
-500 0 500 1000 1500 2000 2500 3000
Time (Sec)
Graph 8
0 27 27
518 100 100
698 100 140
1118 200 200
1254 200 225
1729 300 300
2029 300 330
2389 350 350
2689 350 375
31
Al-50% &PA6-50-%
350
300
250
Temperature (℃)
200
Actual Temp(°C)
150
Deviated Temp(°C)
100
50
0
0 200 400 600 800 1000 1200 1400 1600 1800
Time (Sec)
Graph 9
0 50 50
240 50 80
491 100 100
701 100 110
864 158 158
1164 158 177
1344 275 275
1644 275 300
32
3.6 MICROSTRUCTURE OF VARIOUS COMPOSITIONS
Figure 13 Figure 14
Figure 15
33
3.7 TESTING OF SAMPLES
Hardness test:
The machine on which the samples where tested is Vickers micro hardness testing machine.
Maximum load that the machine can apply is 2 KN
Components of Machine:
➢ Digital display with touch screen setting facility.
➢ Robust base
➢ Micro indenter
➢ Microscope for microstructure of the sample.
Sample should be smoothly polished in order get a clear visibility of indentation and
microstructure.
Figure 16
Procedure:
➢ Place the sample with the smooth finish and flat surface.
➢ Check the porosity of microstructure through the microscope and start the indentation on
the sample by applying certain load on it.
➢ There will one pre time taken option to start the indentation.
➢ After indentation is completed place the indication lines on the two edges horizontally
and vertically in order to get the values of L1&L2
➢ So that Vickers hardness is automatically calculated by the machine.
34
Table 3:
Powder Composition
Sr. No Load (g) L1 (µm) L2 (µm) (L1+L2)/2 Vickers Hardness
Al PA-6 PA-66
500
1 100 - - 172.41 172.41 172.41 31.20366717
2 90 10 - 500 176.42 176.42 176.42 29.80127912
3 90 10 300 158.01 158.01 158.01 22.29013223
4 80 20 500 252.84 242.8 247.82 15.10281266
5 80 20 300 184.36 184.36 184.36 16.37375893
6 80 10 10 300 161.5 172.69 167.095 19.93218373
7 70 30 500 204.9 204.9 204.9 22.09258954
8 70 30 300 192.41 192.41 192.41 15.03233729
9 50 50 300 196.7 192.11 194.405 14.7253942
Compression Test:
The compression test on the samples has been performed on the Fatigue Testing Machine of the
fatigue testing lab of the Department of Mechanical Engineering, GITAM University.
The compression test of eight samples has been performed on Fatigue Testing Machine, make
INSTRON. The sample to be tested is placed on the base plate of the machine.
Gradual loading is applied as shown in the figures. The compressive load makes the samples to
compress under high pressure as shown in the figure. It can be seen that the shape of the sample
is no longer the same.
Due to the application of load the sample loses its structure and shape. The sample bulges at the
center level. This area represents the plastic deformation of the sample due to the application of
load. The graphs regarding this compression have been generated, and are displayed in the
further sections.
35
Figure 17
Figure 18 Figure 19
36
Moisture Absorption Test:
The objective of this test is to determine the amount of moisture absorbed by each powder at room
temperature.
The sample was initially weighed in a weighing pan and was inserted into a vacuum oven. The
temperature was raised up to 60°C and then the weight was measured.
Now the temperature was raised to 65°C and weighed again. The same has been done at 70°C.
All the values have been compared with the initial value of the sample powder and the percentage
absorption of water at every stage have been calculated.
NDT
The main objective of this test is to determine the quality of the sample.
The tests have been performed and the values have been noted down in a tabular form as shown
below.
Table 4
Powder Composition
Sr. No
Al PA-6 PA-66 Time(µsec) Length(mm) Velocity(m/s)
1 100 - - 10 12 1150
2 90 10 - 20.5 10 490
3 90 10 10.4 7 670
4 80 20 11.2 10 890
5 80 20 23.5 10 430
6 80 10 10 15 10 670
7 70 30 16.6 10 600
8 70 30 18.3 10 550
9 50 50 10.4 5 480
Depending on the velocity of wave propagated, the quality of the sample is determined. The more
the velocity the higher is its quality and vice versa.
37
Figure 20
Density Analysis
The density, or more precisely, the volumetric mass density, of a substance is its mass per unit
volume. The symbol most often used for density is ρ (the lower case Greek letter rho), although
the Latin letter D can also be used. Mathematically, density is defined as mass divided by
volume.
Hence it is clear that if the mass and volume of the material is known, then density is easily
calculated.
For this the apparatus has been set up as shown in the figure below.
Figure 21
38
➢ The mass of the sample is first noted down.
➢ Then the sample is dropped into the flask filled with water.
➢ The rise in the level of water is noted down, which is nothing but the volume of the
sample.
➢ Once the volume is available, it is divided under mass and density is calculated.
Table 5
Powder Composition
Density of Relative
Sr. No mass(g) Volume(ml) Density
Al PA-6 PA-66 powder Density
1 100 4.787 2 2.3935 2.7 0.886481481
2 90 10 4.455 2.5 1.782 2.543 0.700747149
3 90 10 3.795 2.5 1.518 2.545 0.596463654
4 80 20 3.023 2 1.5115 2.386 0.633487008
5 80 20 1.872 2 0.936 2.39 0.391631799
6 80 10 10 2.99 2 1.495 2.388 0.626046901
7 70 30 2.194 1.5 1.4626667 2.229 0.656198594
8 70 30 1.471 1 1.471 2.235 0.658165548
9 50 50 2.251 2 1.1255 1.915 0.58772846
39
RESULTS AND DISCUSSION
4.1 COMPACTION CURVES

The values which are obtained from the compaction of the samples have been considered and
different parameters were evaluated. The characteristic calculations are shown below.
SAMPLE 1 ALUMINIUM:-
Diameter (D) =15mm
Powder mass = m = 6g
Initial height (H) = 21mm
Compacted height (h) = 12.8mm
Punch displacement (d) = H-h = 21-12.8
= 8.2mm
Load = 50KN = F
Time taken for compaction (t) = 19.1 seconds
𝐹 50∗10− 3 50∗10− 3
Stress = 𝐴𝑟𝑒𝑎 = 𝑝𝑖 2 = 𝑝𝑖
∗𝑑 ∗152
4 4
= 282.9421 N/𝑚𝑚2
= 282.9421 MPa
Work done (W) = Force (F) * Displacement (d)
= 50 * 8.2
= 410 J
𝑤𝑜𝑟𝑘𝑑𝑜𝑛𝑒(𝑤)
Compaction energy = 𝑚𝑎𝑠𝑠(𝑚)
410
= = 68.334 J/g
6
40
𝑃𝑢𝑛𝑐ℎ𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡(𝑑) 8.2
Punch velocity (V) = = = 0.429319 mm/s
𝑇𝑖𝑚𝑒(𝑡) 19.1
𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦(𝑉)
Strain rate = 𝐼𝑛𝑖𝑡𝑖𝑎𝑙ℎ𝑒𝑖𝑔ℎ𝑡(𝐻)
0.429319
= = 0.02044378 𝑠𝑒𝑐 − 1
21
Table 6
Powder Composition Compaction
Sr. No Work done(J) Velocity (mm/s) Strain rate(1/sec)
Al PA-6 PA-66 energy(J/g)
1 100 - - 410 68.33333333 0.429319372 0.02044378

2 90 10 - 450 112.5 0.520231214 0.020809249
3 90 10 525 150 0.621301775 0.02344535
4 80 20 510 137.8378378 0.675496689 0.025018396
5 80 20 680 212.5 0.937931034 0.033497537
6 80 10 10 800 210.5263158 1.032258065 0.033298647
7 70 30 725 241.6666667 1.050724638 0.032429773
8 70 30 845 291.3793103 1.190140845 0.035955917
9 50 50 750 288.4615385 1.25 0.035714286
TIME VARIATION
20
18
16
14
12
TIME (SEC)
10 19.1
17.3 16.9
8 15.1 15.5
14.5 13.8 14.2
12
6
4
2
0
1 2 3 4 5 6 7 8 9 10
COMPOSITIONS
Graph 10
41
VARIATION OF COMPACTION ENERGY
291.3793103
288.4615385
241.6666667
210.5263158
COMPACTION ENERGY (J/G)
212.5
137.8378378
150
112.5
68.33333333
1 2 3 4 5 6 7 8 9
Graph 11
It can be seen from the above graph that as the composition of polyamide increases in a sample,
the compaction energy required increases.
This phenomenon is due to the increase in punch displacement as the compressibility of

polyamide is greater.
With the increase in compressibility, there is an increase in the punch displacement. Which
means, the work done has increased. It can be seen from the formula of compaction energy that
the compaction energy is directly proportional to the work done.
Hence with the increase in the polyamide concentration, the compressibility increases which
leads to the increase in work done, which in turn leads to the increase in the compaction energy.
42
VARIATION OF STRAIN RATE
0.04
0.035
0.03
Strain Rate (1/sec)
0.025
0.02
0.015
0.01
0.005
0
1 2 3 4 5 6 7 8 9
Series1 0.0204438 0.0208092 0.0234454 0.0250184 0.0334975 0.0332986 0.0324298 0.0359559 0.0357143
COMPOSITIONS
Graph 12
It can be observed from the above data that with the increase in the concentration of polyamide
in a sample, the strain rate has shown a considerable increment.
With the increase in the punch displacement there has been an increase in the velocity.
From the strain energy equation it is clear that the strain rate is directly proportional to the
velocity of the punch.
Since the velocity of the punch is constant, therefore with the rise in velocity of the punch there
is a considerable rise in the strain rate.
That’s the reason why the strain rate has increased with the increase in polyamide concentration.
43
PUNCH DISPLACEMENT VS TIME GRAPHS
Variation of Punch Displacement at 4th second

6
5
4.76056
5
Punch Displacement (mm)
4.12904 4.20288
3.75172
4
3 2.702
2.4852
2.08092
2 1.72632
0
1 2 3 4 5 6 7 8 9
Compositions
Graph 13

12
10
10 9.52112
8.40576
8.25808
8 7.50344
6 5.404
4.9704
4.16184
4 3.45263
0
1 2 3 4 5 6 7 8 9
Compositions
Graph 14
44
16 15
14.2817
14
12.3871 12.6086
12 11.2552
10
8.106
7.4556
8
6.24276
6 5.17895
0
1 2 3 4 5 6 7 8 9
Compositions
Graph 15

18 16.9
16
16 14.5
13.6
14
12
9.9408 10.2
10
8.32368
8 6.90526
0
1 2 3 4 5 6 7 8
Compositions
Graph 16
45
4.2 COMPARISION OF HARDNESS
The hardness values are directly obtained from the Vickers hardness testing equipment.
The basic calculations performed inside the machine is as shown below.
AL:
L1 = 172.41 µm
L2 = 172.41 µm
𝐿1+𝐿2
d= = 172.41 µm
2
5
f = 10 ∗ 9.81 N
Load = 500g
5
0.1891∗𝑓 0.1891∗9.81∗
10
V.H = = = 31.20366 VHN
𝑑2 [172.41∗10− 3]2
Table 7
Powder Composition
Sr. No Load (g) L1 (µm) L2 (µm) (L1+L2)/2 Vickers Hardness
Al PA-6 PA-66
500
1 100 - - 172.41 172.41 172.41 31.20366717
2 90 10 - 500 176.42 176.42 176.42 29.80127912
3 90 10 300 158.01 158.01 158.01 22.29013223
4 80 20 500 252.84 242.8 247.82 15.10281266
5 80 20 300 184.36 184.36 184.36 16.37375893
6 80 10 10 300 161.5 172.69 167.095 19.93218373
7 70 30 500 204.9 204.9 204.9 22.09258954
8 70 30 300 192.41 192.41 192.41 15.03233729
9 50 50 300 196.7 192.11 194.405 14.7253942
46
Variation in Hardness
35
30
25
Vickers Hardness
20
15
10
0
1 2 3 4 5 6 7 8 9 10
Compositions
Graph 17
By careful examination of the graph it can be seen that the hardness abruptly decreases and
increases from the 5th composition. This is because the spring back effect leads to decrease in
density of the compacted briquette. As PA-66 is more elastic in nature when compared to PA-6,
the density variation will be more, due to which the hardness shows a steep decrease.
The hardness value of the pure aluminium and sample 2 are close to each other. This implies that
it may not have much variation in the properties and strength.
47
4.3 VARIATION IN MOISTURE ABSORPTOIN
Table 8
Powder Composition
Sr. No Initial weight wt. at 60℃ wt. at 65℃ wt. at 70℃
Al PA-6 PA-66
1 100 - - 103.027 103.026 103.025 103.023

2 90 10 - 107.77 107.75 107.66 107.59
3 90 10 99.25 99.25 99.23 99.15
4 80 20 94.29 94.27 94.26 94.24
5 80 20 102.95 102.94 102.93 102.92
6 80 10 10 102.88 102.81 102.75 102.69
7 70 30 103.06 103.04 103.02 102.99
8 70 30 94.31 94.28 94.27 94.26
9 50 50 94.3 94.24 94.19 94.14
𝐼𝑛𝑖𝑡𝑖𝑎𝑙𝑤𝑒𝑖𝑔ℎ𝑡−𝐹𝑖𝑛𝑎𝑙𝑤𝑒𝑖𝑔ℎ𝑡
% of moisture absorbed = ∗ 100
𝑖𝑛𝑖𝑡𝑖𝑎𝑙𝑤𝑒𝑖𝑔ℎ𝑡
103.027−103.026
% of moisture absorbed at 60℃ = ∗ 100
103.027
= 0.000970619%
103.027−103.025
% of moisture absorbed at 65℃ = * 100
103.027
= 0.001949239%
103.027−103.023
% of moisture absorbed at 70℃ = ∗ 100
103.027
= 0.003882477%
48
Table 9
Powder Composition
%age absorption at %age absorption at %age absorption at
Sr. No
60℃ 65℃ 70℃
Al PA-6 PA-66
1 100 - - 0.0009706 0.001941239 0.003882477
2 90 10 - 0.018558 0.102069221 0.167022362
3 90 10 0 0.020151134 0.100755668
4 80 20 0.0212112 0.031816736 0.053027893
5 80 20 0.0097135 0.019426906 0.029140359
6 80 10 10 0.0680404 0.126360809 0.184681182
7 70 30 0.0194062 0.038812342 0.067921599
8 70 30 0.03181 0.042413318 0.053016647
9 50 50 0.0636267 0.116648993 0.169671262
Variation in Moisture Absorption

0.2
0.18
0.16
0.14
Absorption (%)
0.12
0.1
0.08
0.06
0.04
0.02
0
1 2 3 4 5 6 7 8 9 10
Composiitons
%age absorption at 60℃ %age absorption at 65℃ %age absorption at 70℃
Graph 18
It can be seen that there is no much variation in the percentage absorption of moisture.
49
4.4 COMPRESSION CURVES
Aluminium
160
140
120
100
Stress (MPa)
80
60
40
20
0
-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3
-20
Compressive Strain
Graph 19
Table 10
Axial
Compressive Load at Gauge
strain at Maximum Length
Specimen Maximum Compressive Maximum Comp. Modulus (Strain
label Load Strength Comp. load load (Automatic) Source)
(N) (MPa) (mm/mm) (kN) (MPa) (mm)
-
1 Sample 1 26088.8 147.63 0.25893 -26.08878 1257.95 12.00009
-
Mean 26088.8 147.63 0.25893 -26.08878 1257.95 12.00009
Standard
Deviation
-
Minimum 26088.8 147.63 0.25893 -26.08878 1257.95 12.00009
-
Maximum 26088.8 147.63 0.25893 -26.08878 1257.95 12.00009
Range 0 0 0 0 0 0
Calculated Toughness = 16.15kJ
50
Al-90% & PA6-10%
80
70
60
50
Stress (MPa)
40
30
20
10
0
-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
-10
Compressive Strain
Graph 20
Table 11
Axial
-
1 Sample 2 8051.71 45.56 0.1379 -8.05171 629.9716 13.0021
-
Mean 8051.71 45.56 0.1379 -8.05171 629.9716 13.0021
Standard
Deviation
-
Minimum 8051.71 45.56 0.1379 -8.05171 629.9716 13.0021
-
Maximum 8051.71 45.56 0.1379 -8.05171 629.9716 13.0021
Range 0 0 0 0 0 0
51
Al-90% & PA 66-10%
60
50
40
Stress (MPa)
30
20
10
0
-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
-10
Compressive strain
Graph 21
Table 12
Axial
Gauge
Compressiv Load at Length
e strain at Maximu Modulus (Strain
Specime Maximu Compressiv Maximum m Comp. (Automatic Source
n label m Load e Strength Comp. load load ) )
1 alu_sam3 9070.49 51.33 0.13353 -9.07049 833.786 -13
Mean 9070.49 51.33 0.13353 -9.07049 833.786 -13
Standard
Deviation
Minimum 9070.49 51.33 0.13353 -9.07049 833.786 -13
Maximu
m 9070.49 51.33 0.13353 -9.07049 833.786 -13
Range 0 0 0 0 0 0
52
Al-80% & PA6-20%
60
50
40
Stress (MPa)
30
20
10
0
-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
Compressive Strain
Graph 22
Table 13
Axial
-
1 alu_sam4 8297.02 46.95 0.31775 -8.29702 171.6639 10.9991
-
Mean 8297.02 46.95 0.31775 -8.29702 171.6639 10.9991
Standard
Deviation
-
Minimum 8297.02 46.95 0.31775 -8.29702 171.6639 10.9991
-
Maximum 8297.02 46.95 0.31775 -8.29702 171.6639 10.9991
Range 0 0 0 0 0 0
53
Al-80% & PA66-20%
16
14
12
10
Stress (MPa)
0
-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
-2
Compressive strain
Graph 23
Table 14
Axial
-
1 alu_sam5 2314.89 13.1 0.32101 -2.31489 68.68568 12.0001
-
Mean 2314.89 13.1 0.32101 -2.31489 68.68568 12.0001
Standard
Deviation
-
Minimum 2314.89 13.1 0.32101 -2.31489 68.68568 12.0001
-
Maximum 2314.89 13.1 0.32101 -2.31489 68.68568 12.0001
Range 0 0 0 0 0 0
54
Al-80% PA6-10% & PA66-10%
40
35
30
25
Stress (MPa)
20
15
10
0
-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
-5
Compressive Strain
Graph 24
Table 15
Axial
-
1 alu_sam6 5921.47 33.51 0.35811 -5.92147 112.1615 10.9992
-
Mean 5921.47 33.51 0.35811 -5.92147 112.1615 10.9992
Standard
Deviation
-
Minimum 5921.47 33.51 0.35811 -5.92147 112.1615 10.9992
-
Maximum 5921.47 33.51 0.35811 -5.92147 112.1615 10.9992
Range 0 0 0 0 0 0
55
Al-70% & PA6-30%
9
6
stress (MPa)
0
-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Compressive Strain
Graph 25
Table 16
Axial
1 alu_sam7 1356.96 7.68 0.1531 -1.35696 103.8728 -9.99933
Mean 1356.96 7.68 0.1531 -1.35696 103.8728 -9.99933
Standard
Deviation
Minimum 1356.96 7.68 0.1531 -1.35696 103.8728 -9.99933
Maximum 1356.96 7.68 0.1531 -1.35696 103.8728 -9.99933
Range 0 0 0 0 0 0
56
Al-70% & PA66-30%
3.5
2.5
2
Stress (MPa)
1.5
0.5
0
-0.05 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
-0.5
Compressive Strain
Graph 26
Table 17
Axial
Compressiv Load at Gauge
e strain at Maximu Modulus Length
Specimen Maximu Compressiv Maximum m Comp. (Automatic (Strain
label m Load e Strength Comp. load load ) Source)
1 alu_sam8 520.49 3.92 0.43659 -0.52049 11.03473 -9.99943
Mean 520.49 3.92 0.43659 -0.52049 11.03473 -9.99943

Standard
Deviation
Minimum 520.49 3.92 0.43659 -0.52049 11.03473 -9.99943

Maximu
m 520.49 3.92 0.43659 -0.52049 11.03473 -9.99943
Range 0 0 0 0 0 0
57
4.5 DENSITY ANALYSIS
Table 18
Powder Composition Density of

Sr. No powder Relative Density Porosity
Al PA-6 PA-66
(gram/cc)
1 100 2.7 0.886481481 0.113518519
2 90 10 2.543 0.700747149 0.299252851
3 90 10 2.545 0.596463654 0.403536346
4 80 20 2.386 0.633487008 0.366512992
5 80 20 2.39 0.391631799 0.608368201
6 80 10 10 2.388 0.626046901 0.373953099
7 70 30 2.229 0.656198594 0.343801406
8 70 30 2.235 0.658165548 0.341834452
9 50 50 1.915 0.58772846 0.41227154
Porosity Variation
0.7
0.6
0.5
POROSITY
0.4
0.3
0.2
0.1
0
0 1 2 3 4 5 6 7 8 9 10
COMPOSITIONS
Graph 27
58
CONCLUSION
The material Alumide is a blend of aluminium and polyamide powder produced by compact
sintering using muffle furnace.
• Three compositions of Alumide having hardness value close to Aluminium hardness
value i.e. 31.2 VHN
Sample no. Vickers hardness
2 29.80127912
3 22.29013223
7 22.09258954
• One composition of that material achieved the toughness value bit more than the
aluminium value i.e. 16.15 KJ and another value which is close to aluminium toughness.
Sample No Toughness (KJ)

2 16.4614
4 10.572
• Moisture content in all the compositions are less than 0.5 percent which could be
negligible.
• NDT techniques are used to determine the quality of the material, sample with high
pulse velocity i.e. greater than 600m/s will have more quality.
(i) Also depends upon method of producing the sample
(ii) Sample NDT details are as follows:
Sample no. Velocity(m/s)

4 890
6 670
• Porosity result of the different compositions increases as the polyamide content increases
as the relative density decreases.
59
• But As there is a lot decrease in relative density which will lead to weight reduction in
large scale in heavy duty applications like inner lining of aircraft.
• Better surface finish with less porosity can be obtained by additive manufacturing
technique by SLS Machine since we performed compact sintering.
Finally, Recommended material for

Quadcopter frames and Aerospace applications : SAMPLE 2
Jewelry applications or low hardness applications : SAMPLE 4
60
REFERENCES
1) Effect of Powder Type and Compaction Pressure on the Density, Hardness and
Oxidation Resistance of Sintered and Steam-treated Steels.
-Wen-Fung Wang
-(Submitted January 18, 2006; in revised form September 21, 2006)
2) Polymer–Nano filler Prepared by High-Energy Ball Milling and High Velocity Cold
Compaction
-Bruska Azhdar,1 Bengt Stenberg,1 Leif Kari2
-1 Department of Fiber and Polymer Technology, Royal Institute of Technology,
KTH, SE- 100 44 Stockholm, Sweden 2 The Marcus Wallenberg Laboratory
for Sound and Vibration Research, KTH, SE-100 44 Stockholm, Sweden
3) Consolidation phenomena in laser and powder-bed based layered manufacturing

-J.-P. Kruth1 (1), G. Levy2 (1), F. Klocke3 (1), T.H.C. Childs 4 (1) 1
K.U.Leuven, Division PMA, Leuven, Belgium 2 FHS - University of Applied
Sciences St. Gallen, Switzerland 3 Fraunhofer, Institute for Production
Technology IPT, Aachen, Germany 4 University of Leeds, School of Mechanical
Engineering, UK
4) Working Pressure, Deformation Modes and Fracture in Open Piercing of

Cylindrical Disks Made of Compacted Sintered Aluminium Powder
-N. R. Chitkara1 and G. H. Liaghat2
-Applied Mechanics Division, Department of Mechanical Engineering, the
University of Manchester Institute of Science and Technology, Sackville Street,
Manchester M60 1QD, UK; and 2 Applied Mechanics Division, Department of
Mechanical Engineering, Tarbiat Modares University, P.O. Box 14155-4838,
Tehran, Iran
61
5) Effect of loading time on the between hardness and stress
-G. D. Del' and F. Kh. Tomilov
6) The circumferentially notched cylindrical bar as a fracture toughness test specimen

-by W. F. Brown, Jr. Lewis Research Center Cleveland, Ohio TECHNICAL
PAPER proposed for presentation at Symposium on Linear Fracture Mechanics
sponsored by Lehigh University Bethlehem, Pennsylvania, July 29-30, 1974
7) Improved High Velocity Cold Compaction Processing: Polymer Powder to High

Performance Parts
-Bruska Azhdar KTH Royal Institute of Technology 19 PUBLICATIONS 213
CITATIONS
8) www.wikipedia.org
9) www.pm-review.com
62

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EVALUATION PROPERTIES OF

ALUMINIUM - POLYAMIDE (ALUMIDE)

Under the esteemed guidance of

Shri BH. LAKSHMIPATHI. RAJU

DEPARTMENT OF MECHANICAL ENGINEERING,

This is to certify that the project entitled “Evaluation properties of Aluminium

Shri BH. LAKSHMIPATHI. RAJU Prof. Dr. M. R. S. SATYANARAYANA

We, hereby declare the project entitled “EVALUATION PROPERTIES OF

We consider it a privilege to express our gratitude and respect to Dr. M. R. S. Satyanarayana,

ASIF BAIG Regd. No. 1210814404

used in heavy duty applications.

2.1 Application oriented troubles with aluminum 10

3.1 Materials Used 17

4 RESULTS AND DISCUSSION 40

4.1 Compaction Curves 40

LIST OF FIGURES: PAGE NO.

• Figure 1 – Literature review sample graphs 11

• Table 1 – Weight Composition of powders 17

• Graph 1-9 – Sintering cycles for various compositions 24

1.2 POWDER METALLURGY

1.3 POWDER COMPACTION

1.7 PROPERTIES AND APPLICATIONS OF PA6:

Main Applications of polyamide 6 includes:

Physical Properties Metric

Mechanical Properties Metric

Electrical Properties Metric

PA66 Applications in Automotive/Transportation

1 Excellent surface appearance

2 Good paint ability

4 High heat resistance

5 Good chemical resistance

6 Outperforming toughness and fatigue resistance

7 Excellent flow characteristics

8 Short injection cycle times

9 Superior weld line strength at elevated temperatures

11 Good surface finish

12 Easy and speedy process-ability.

2.1 APPLICATION ORIENTED TROUBLES WITH

2.2 COMPACTION STUDY

Punch Movement terminology:

2.3 SPRING BACK GRADIENT

Figure 2: Relaxation Assist

2.4 CONSOLIDATION MECHANISM

2.5 FUTURE ADVANCES

3.1 MATERIALS USED

Average grain size: 40 µm

Average grain size: 40 µm

3.2 WEIGHT COMPOSITIONS OF POWDERS

Maximum operating temperature: 1000 °C

Time(Sec) Actual Temp(°C) Deviated Temp(°C)

150 Deviated Temp(°C)

Time(Sec) Actual Temp(°C) Deviated Temp(°C)

1138 150 150

1438 150 180

2158 300 300

2458 300 340

Time(Sec) Actual Temp(°C) Deviated Temp(°C)

1108 150 150

1397 150 176

2122 300 300

2405 300 336

1967 250 289

2120 300 300

2300 300 324