Consolidation by MF-ERS of mechanically alloyed Al powder

Abstract The aim of this work is to study the viability of producing, by medium-frequency electrical resistance sintering (MF-ERS), compacts from mechanically alloyed aluminium powders. The MF-ERS process was carried out using different values of current intensity (6, 8, 10 and 11 kA) and dwelling (heating) times (400, 700 and 1000 ms). Results were compared with compacts processed by the conventional cold pressing and sintering route (850 MPa and 650 °C-1h). Depending on the processing route different properties were obtained. The final porosity of the MF-ERS compacts (23.6–7%) can be as low, under the tougher tested sintering conditions, as that of the conventionally produced compacts (6%). The compacts obtained by MF-ERS are less ductile, with lower compression strength than that obtained by the conventional route. Furthermore, a similar electrical resistance and higher microhardness can be reached by the MF-ERS process, despite the duration of the consolidation process is only a fraction of that of the conventional process.