Modelling of aluminum powder densification kinetics during electric pulse consolidation

Keywords

aluminum, spark plasma sintering, densification kinetics, current super¬posi¬tion, energy efficiency.

Cite as

Syzonenko O. M., Prystash M. S., Torpakov A. S., and Makrukha T. O. Modelling of aluminum powder densification kinetics during electric pulse consolidation. Physicochemical Mechanics of Materials. 2026. 62(4), 15-24.

Abstract

The comparative results of densification kinetics of aluminium powder (grade PA1, d₀ = 21 mm) were obtained under four current modes – direct current, alternating (50 Hz), pulsed (1 kHz), and their superposition – over a current range of 400…800 A and compac­tion pressures of 20–50 MPa. It is shown that DC provides the highest heating rates (up to 15.26°C/s at 800 A) but proves to be the most energy-intensive mode, consuming up to 0.726 kJ. It is established that pulsed current at 1 kHz provides a relative density of 0.98 at 800 A and 50 MPa while maintaining safe heating rates. The hybrid superposition mode of DC and pulsed components is technologically optimal: the synergistic action of both me­chanisms yields a relative density of 0.985 at minimum energy consumption of 0.367 kJ. It is shown that densification kinetic curves exhibit a sigmoidal (S-shaped) profile regardless of current type, and experimental validation on real aluminium compacts confirmed the theoretical predictions.