Optimization of pure aluminum powder metallurgy compacts with ultra-high frequency induction sintering: Duration, energy, and mechanical performance analysis

This study compared the efficacy of Ultra-High Frequency Induction Sintering (UHFIS) against conventional furnace sintering for the production of pure aluminum Powder Metallurgy (PM) compacts. The comparison was based on parameters such as cost, energy consumption, process time, density, and hardness. The UHFIS process was performed using a 2.8 kW, 900 kHz system at 600 degrees C for six different durations (1 to 10 min). Conventional sintering, conversely, lasted 60 min at 600 degrees C. The results demonstrated that an increase in UHFIS duration led to a linear rise in energy consumption and cost. However, a 5-minute UHFIS duration was observed to optimize hardness and density values while keeping costs controlled. The UHFIS method provided a significant advantage by reducing the process time by a factor of 12 compared to conventional sintering. Conversely, due to its lower energy consumption, conventional furnace sintering offered a cost that was three times lower than UHFIS. In conclusion, the shorter process time and increased production capacity effectively compensate for the higher costs of UHFIS. With an optimized sintering duration, the UHFIS method exhibits significant potential for the efficient and economical production of high-quality aluminum PM compacts in industrial and mass production settings.