Influence of processing parameters on the mechanical properties of Electro-Sinter-Forged iron based powders

Abstract The paper investigates the effects of the processing parameters of an innovative electro-discharge sintering process named Electro-Sinter-Forging applied to a Fe–Cr–Mo powder. Consolidation is obtained by the superposition of a single electromagnetic pulse with a single mechanical pulse. Two high-speed numerically controlled axes are used in the manufacturing process, operating in synchrony with the electromagnetic pulse. Through an analysis of covariance (ANCOVA) on the experimental data, the differences and correlations in density, pressure before discharge and after discharge, the thermal energy from Joule heat and the transverse rupture strength (TRS) are evidenced. Fracture surfaces are observed and analyzed. A comparison with the conventional press and sinter production process is also performed.