Modelling of aluminium composite consolidated with spark plasma sintering

Aluminium-based composite processed with spark plasma sintering was modelled with COMSOL Multiphysics. This was aimed at investigating the effect of the SPS process parameters on thermal and mechanical stresses induced in the sintered Al-CNTs-Nb composite samples. The modelling employed optimal parameters used in the laboratory to fabricate the samples. The physics included electro-thermo-mechanical coupling. The geometry was 2D axisymmetric while the parameters were based on temperature-dependent properties. Only the consolidated sample was modelled and simulated to simplify the modelling. Results obtained showed that the simultaneous heating and application of pressure enhanced the sintering efficiency and the properties of the product. The least von Mises stress as well as least thermal stress were obtained at a pressure of 30 MPa as against 20 MPa and 10 MPa. This implied that higher pressure produced lower stresses. Therefore, it can be concluded that high sintering pressure reduces mechanical and thermal stresses and improves the properties of the composite.