Power Point on Powder Compaction

1. Powder Compaction
Dr.R.Narayanasamy,B.E.,M.Tech.,M.Engg.,Ph.D.,(D.Sc)
Professor, Department of Production Engineering ,
National Institute of Technology,
Tiruchirappalli - 620015,
Tamil Nadu, India.
Email id’s: narayan@nitt.edu
&
narayan10455@yahoo.co.in
By

2. Steps in Making Powder Metallurgy Parts
Outline of processes and operations involved in making powder-metallurgy parts.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

3. Powder compaction methods
 Unidirectional (die) pressing: Single action pressing
 Double action pressing
 Isostatic pressing
 Powder rolling
 Stepwise pressing
 Powder extrusion: powder direct; powder canned
 Powder swaging
 Explosive compacting
 Powder forging

4. Die compaction
 Consolidation of powder by the application of uniaxial
stress while the powder is constrained in rigid tooling.
 Powders from the feed hopper at apparent density in
placed in die cavity.
 Particles rearrange, deform and bond because of pressure
applied by punch.
 Deformation hardens the particles and hence, more
pressure is applied to the powder.
 After attaining maximum hardness, there is no density
change with further application of compaction pressure.
 The compaction pressure ranges up to 1000MPa. (Depends
on powder and tool material)
 Soft powders (ex: Al powders attains more green density
(~90%) with less compaction pressure ~ 150 MPa)
 Hard powders (ex: cemented carbide attains ~ 60% green
density for the compaction pressure of ~175MPa).

5. Die compaction process

6. Green Compaction tool for P/M
(Uni directional compaction)

7. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Compaction
(a) Compaction of metal powder to form a bushing. The pressed-powder part is called
green compact. (b) Typical tool and die set for compacting a spur gear. Source: Courtesy
of Metal Powder Industries Federation.

8. Parts Made by Powder-Metallurgy
(a) Examples of typical parts made by powder-metallurgy processes. (b) Upper trip lever for a
commercial sprinkler made by P/M. This part is made of an unleaded brass alloy; it replaces a
die-cast part with a 60% savings. (c) Main-bearing metal-powder caps for 3.8 and 3.1 liter
General Motors automotive engines. Source: (a) and (b) Reproduced with permission from
Success Stories on P/M Parts, 1998. Metal Powder Industries Federation, Princeton, New Jersey,
1998. (c) Courtesy of Zenith Sintered Products, Inc., Milwaukee, Wisconsin.
a)
b)
c)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

9. Conventional P/M Route
Compaction relative density R=(ρf /ρth) > 0.70 (or)
70%
During sintering, there is 4 to 5% increase in R
During cold working, (Example: Cold upsetting) there
is 12% increase in R
During hot working, there is more than 20% increase
in R

10. (a) (b) (a) (b)
Pressures mobilized during
single action die compaction, a)
without and b) with lubricant.
Pressures mobilized during a)
free mould (wet – bag) and b)
fixed mould (dry – bag) isostatic
compaction.

11. Schematic of experimental
triaxial compaction chamber

12. Unidirectional compaction: Single action
pressing
 Vertical pressure is applied to powder
 Friction occurs between powder and die walls
 Non uniform pressure distribution along sides of
compacts
 Pressure gets reduced at the base of compacts.

13. Unidirectional compaction: Double
action pressing
 Produce equal pressure at top and bottom of compacts
 Friction in side walls are reduced by lubricants which
enhances the lateral pressure
 Final global stress state is not uniform
 Parts with large height to diameter ratios and complex
shapes cannot be compacted
 But, used in where large production rates are required

14. Isostatic compaction/ Hydrostatic
compaction
 Powder is placed in a flexible mould (rubber) and
immersed into a pressure vessel and compacted using
hydorstatic pressure
 This method is flexible with part size and shape
 The final global stresses are isostatic around the compacts
 The production rate is low. To overcome this, a slight
modification with fixed mould (upper and lower end with
rigid part) and side walls with rubber was introduced
 This modified setup leads to low axial pressure than lateral
pressure

15. Triaxial compaction
 Setup is similar to fixed mould isostatic pressing
 Lateral and axial pressures can be controlled separately
 Shear stress within compacts enhance green density and
strength
 Torsional shear stress is applied (either by load piston or
rotation of tool)
 The minor principal stress (σ3) is uniform in all directions
 Axial pressure is applied by the piston which increases axial
stress (σ1)
 The resulting principal stress difference (σ1 - σ3 = 2τ)
 The above is nothing but Tresca Yield criteria

17. Mohr stress space diagrams
 In fig. (a), confining pressure is increased to produce σ3 in all
directions (horizontal dotted line)
 Axial stress (σ1) is increased along with increase in average
normal stress and also produce a shear stress (angular dotted
line)
 The various combinations of stress paths are shown in fig. (b).
 Stress path (1) reduces total time of compaction with low green
density compared to other stress paths.
 Stress path (5) produces high green density compacts with high
confining pressure than other stress paths.
 Stress path (3) is the representation of fig.(a) which is optimum.
 There is a limit for shear stress for compaction in rigid moulds.
Further increase in shear stress will lead to shear failure.
 A failure plane propagation is approximately 45°

19. Stress and volumetric strain versus axial strain
response curves for green iron compacts at various
confining pressures.
 The peak stress in each curve denotes shear failure.
 Increasing confining pressure increases the principal stress
difference (shear stress). Hence, the sample’s shear strength is
increased.
 Axial strain at failure increases with decreasing confining pressure.
 As the difference between principal stresses increases, the axial
strain at failure also increases.
 Modulus of elasticity increases with increasing confining pressure.
 Green density also increases with increasing in confining pressure.
 Volume decrease is high when the compacts have low green density
(or) the difference between principal stresses decreases.
 Under shear stress, different types of iron powders behave similarly.

20. σ2
σ3
σ1
σ
τ1
τ3
τ2
τ
Mohr’s circle representation
of a three-dimensional state
of stress.
σ2

21. Mohr’s circle (three – dimensional) for the state of
stress
Uniaxial tension
- σ σ
σ1
τ max=σ1/ 2
τ
σ2 = σ3 = 0
(a
)
3
2

22. Mohr’s circle (three – dimensional) for the state of
stress
Uniaxial compression
σ1 = σ2 = 0
σ3
τ
max
2
1

23. Mohr’s circle (three – dimensional) for the state of stress
biaxial tension
σ3 = 0
σ2
σ1
τ max =
τ2
τ1 τ3
3
σ2
σ1 = 2σ2

24. Mohr’s circle (three – dimensional) for the state of stress
biaxial compression
σ1
σ3 = 0
τ1τ3
σ2
σ2
3
τ max =
τ2
σ1 = 2σ2

25. Mohr’s circle (three – dimensional) for the state of stress
triaxial tension (unequal)
σ1
σ2 = σ3
τ max = τ2 =τ3
σ3
σ2
σ1 = 2σ2 = 2σ3

26. Mohr’s circle (three – dimensional) for the state of stress
triaxial compression (unequal)
σ2 = σ3
σ1
τ max = τ2 =τ3
σ2
σ3

27. Mohr’s circle (three – dimensional) for the state of stress
uniaxial tension plus biaxial compression
σ2 = σ3
σ1
τ max = τ2 =τ3
σ3
σ2
σ1 = -2σ2 = -2σ3

29. Failure envelope on Mohr stress space for green
iron compacts
 Curve drawn tangent to Mohr’s circles indicates the
failure envelope.
 Above this shear stress, failure takes place by shear.
 The failure envelope is in a linear pattern with
approximately 5° angle to the horizontal line.
 This is in good agreement with Schwartz et al.
 In empirically fitted log-log sheet, the equation of
failure curve is τ = 3.52 σ ^ 0.48
where τ – shear stress and σ – normal stress.

30. ISOSTATIC DENSITY
AT 100 ksi = 90.4%
PERCENTAGETHEORITICAL
DENSITY
SHEAR STRESS τ , ksi
0 20 40 60 80 100 120
PRINCIPAL STRESS DIFFERENCE σ1 – σ3 , ksi
For decreasing
confining pressure

31. 6 6.5 7
EDGE
CTR.
EDGE
ISOSTATIC AT 30,000 psi
GREEN DENSITY GREEN DENSITY
ISOSTATIC AT 60,000 psi
EDGE
CTR.
EDGE
6.5 7 7.5
Radial density gradients of isostatically compacted iron powder at
different levels of confining pressure. (1 ksi = 6.9 MPa.)

32. 6.5 7 7.5
EDGE
CTR.
EDGE
Radial density gradients of triaxially compacted iron powder at
different levels of confining pressure. (1 ksi = 6.9 Mpa.)
GREEN DENSITY
TRIAXIAL AT 30,000 psi
7 7.5 8
TRIAXIAL AT 60,000 psi
EDGE
CTR.
EDGE

33. Radial density gradients of isostatically and
triaxially compacted iron powder at different
levels of confining pressure
 Atomized iron powder was used in this study.
 Radial density variation was measured by subsequently
machining the compacts up to the core.
 At 30,000 psi, Isostatic compact has high density at edge than
centre (variation: ~ 0.23g/cm^3).
 Particles closer to the edge are plastically deformed and
compacted compared to the core.
 At 60,000 psi, Isostatic compaction shows less density variation
(~ 0.10 g/cm^3) across the radial distance.
 At 30,000 psi, triaxial compaction shows same tendency with
density variation of ~ 0.19 g/cm^3.
 At 60,000 psi, triaxial compaction shows no density variation
across the radial distance.

34. Vertical density gradients of isostatically compacted iron powder at
different levels of confining pressure. (1 ksi = 6.9 Mpa.)

35. Vertical density gradients of triaxially compacted iron powder at
different levels of confining pressure. (1 ksi = 6.9 Mpa.)

36. Vertical density gradients of isostatically and
triaxially compacted iron powder at different
levels of confining pressure
 Vertical density variation was obtained by sectioning the
compacts horizontally.
 At 30,000 psi, isostatic compaction shows high density at centre
than top and bottom with a density variation of ~0.2 g/cm^3.
 At 60,000 psi, isostatic compaction shows density variation of
~0.15g/cm^3
 At 30,000 psi, triaxial compaction shows higher overall density
with less variation of density between top and bottom.
 At 60,000 psi, triaxial compaction shows density variation of ~
0.03g/cm^3
 Triaxial compaction is better than isostatic compaction.
 As the H/D ratio of compact increases, the density variation will
be larger.

37. 60
70
80
90
100
0 20 40 60 80 100
No Shear
High Shear
Medium Shear
Low Shear
TRANSVERSE RUPTURE STRENGTH (ksi)
PERCENTTHEORETICALDENSITY
Density versus transverse rupture strength for isostatically and triaxially
compacted on powder compacts showing the influence of shear stress: no shear;
low shear (0-17 ksi); medium shear (17-24 ksi); high shear (34-50 ksi). (1 ksi = 6.9
MPa.)

38. Density versus transverse rupture strength for
isostatically and triaxially compacted on powder
compacts showing the influence of shear stress
 For the given green density, compacts formed under
high shear stress have greater strength.
 At 90% theoretical density, compacts formed by high
shear stress have more than twice the strength of
isostatic compacts.
 Shear stress during compaction increases the green
density and the strength.

39. Triaxial compaction provides improved green density and strength than others.

40. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Density as a Function of
Pressure and the Effects of
Density on Other Properties
(a) Density of copper- and iron-powder
compacts as a function of compacting pressure.
Density greatly influences the mechanical and
physical properties of P/M parts. (b) Effect of
density on tensile strength, elongation, and
electrical conductivity of copper powder.
Source: (a) After F. V. Lenel, (b) IACS:
International Annealed Copper Standard (for
electrical conductivity).

41. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Density Variation in Compacting Metal
Powders
Density variation in compacting metal powders in various dies: (a) and (c) single-action
press; (b) and (d) double-action press. Note in (d) the greater uniformity of density from
pressing with two punches with separate movements when compared with (c). (e)
Pressure contours in compacted copper powder in a single-action press. Source: After P.
Duwez and L. Zwell.

42. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Compacting Pressures for Various Powders

43. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Press for Compacting Metal Powder
A 7.3-mn (825-ton) mechanical
press for compacting metal
powder. Source: Courtesy of
Cincinnati Incorporated.

44. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Capabilities Available from P/M Operations
Capabilities, with respect to part size and shape complexity, available form various P/M
operations. P/F means powder forging. Source: Courtesy of Metal Powder Industries
Federation.

45. Compaction of Metal Powders by Cold
Isostatic Pressing
 Metal powder is placed in a
flexible rubber mold made
of neoprene rubber,
urethane, polyvinyl
chloride (PVC).
 The assembly is then
pressurized hydrostatically
in a chamber, by water.
 Most common pressure:
400MPa.

46. Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Cold Isostatic Pressing
Schematic diagram of cold isostatic pressing, as applied to forming a tube. The powder
is enclosed in a flexible container around a solid-core rod. Pressure is applied
isostatically to the assembly inside a high-pressure chamber. Source: Reprinted with
permission from R. M. German, Powder Metallurgy Science, Metal Powder Industries
Federation, Princeton, NJ; 1984.

47. Die insert and liner
 It is a removable liner used to minimize too wear,
which is fabricated out of hard materials (ex:
cemented carbide)
 Die insert will be in contact with the component.
 A liner is similar to this, formed as a coating or hard
electroplated layer

48. Die wall friction
 Applied uniaxial load makes the powder to deform and
spread laterally.
 This lateral pressure is against the tooling and creates
wall friction.
 Wall friction reduces powder flow and sliding during
compaction.
 Continual pressure loss with distance from the punch
as the powder bleeds off the applied pressure in the
form of die wall friction.

49. Die wall lubrication
 External spray is dispersed on the die wall after every
compaction.
 The die wall lubrication is introduced via seal ring
built into the lower punch. As the punch moves to the
fill position, it will leave a lubricant film on the die
walls.
 Electrostatic spray with an external dispersion unit.
 Lubricant can be mixed with powders
 Molybdenum disulphide is used as lubricant

50. Compaction of Metal Powders by
other Processes
Rolling:
 Powder is fed to the
roll gap in 2-high
rolling mill, and is
compacted into a
continuous strip at
speeds of up to 0.5 m/s.
 Rolling process carried
out at room or at elevated
temperature.
 Common parts: Sheet
metal for electrical and
electronic components
and for coins.

51. Compaction of Metal Powders by
other Processes
 Powder Extrusion:
Powder is incased in a metal container and extruded.
After sintering, preformed PM parts may be reheated and
then forged in a closed die to their final shape.

52. Sinter forging
 Applicable for ceramic parts
 Ceramic deformation takes
place at a very slow strain rate.
 Limited plastic flow capacity
(for hot ceramics stress and
stain will be low)
 The cycle time is long.
 The slow deformation appears
like forging.
 The stress is low and the
densification and shaping rates
are controlled by diffusional
creep.

53. Powder sinter forging
 No sintering stage is involved.
 Loose powders are compacted and then hot forged.
 This is called sinter forging

54. Advantages of sinter forging

55. Powder compaction equations
 Balshin equation:
 Heckel equation:

56. Powder compaction equations cont…
 Panelli and Ambrozio Filho equation:
 Ge equation:
Where
D- relative density of the compacted material
P- applied pressure
and others are constants

57. Powder compaction equation cont…
Findings of Narayanasamy et al.
 The compaction data were best fitted to the Ge
equation for studying the densification behavior of
nano composite.
The above is Narayanasamy and Jeyasimman work
for AA 6061 nano composites reinforced with hybrid
(TiC + Al2O3) nano particles.

58. Powder compaction equations cont…
 Van Der Zwan and Siskens equation:
Where
D – relative density of the post compacts
- relative apparent density
and others are constants
Van Der Zwan and Siskens equation is the well fitted equation
according to Narayanasamy and Sivasankaran.
It can be used for analyzing the compaction behavior of powders
as applicable and useful to P/M industries.
D0

59. Theory of Plasticity for powder - sinter
forging
 Uniaxial stress state condition:
In the compression of a P/M part, under frictional conditions,
the average density is increased. Friction enhances densification
and at the same time decreases the height reduction at fracture.
The state of stress in a homogeneous compression process is as
follows:
According to Abdel-Rahman et al.
σz = −σeff , σr = σθ = 0 – (1)
where
σz - axial stress
σeff - effective stress
σr - radial stress
Σθ - Hoop stress.

60. Theory of Plasticity for powder -
sinter forging cont ….
- (2)
σm - mean or hydrostatic stress
- (3)
ε0 – hoop strain
εz – axial strain
D0 – initial diameter of the compacts
Df – contact diameter after deformation

61. Theory of Plasticity for powder
- sinter forging cont ….
Where
H0 - initial height of the compacts
Hf – fracture height of the compacts
When the compression continues, the final diameter increases and the
corresponding hoop strain, which is tensile in nature, also increases until it
reaches the fracture limit. Once the fracture is initiated, the forming limit strain is
the same as the effective strain. It is determined from:

62. Theory of Plasticity for powder -
sinter forging cont ….
As an evidence of experimental investigation implying
the importance of the spherical component of the
stress state on fracture according to Vujovic and
Shabaik proposed a parameter called a formability
stress index ‘β’ which is given by:
This index determines the fracture limit

63. Theory of Plasticity for powder - sinter
forging cont ….
 Plane stress state condition
According to Narayanasamy and Pandey, the state of
stress in a plane stress condition is as follows:
where σeff is the effective stress,
Where α is the Poisson’s ratio and σz is the axial stress in upsetting.

64. Theory of Plasticity for powder - sinter
forging cont ….
Since the radial stress, σr is zero at the free surface it
follows from the flow rule that:
σm - mean or hydrostatic stress is :
The hoop strain (εθ) of the compact is determined
by this equation
where
Db - bulged diameter of the
compacts
Dc - contact diameter of the
compacts
Do - initial diameter of the
compacts.

65. Theory of Plasticity for powder - sinter
forging cont ….
 Triaxial stress state condition
According to Narayanasamy and Ponalagusamy,
The state of stress in a triaxial stress condition is given as
follows:

66. Theory of Plasticity for powder - sinter
forging cont ….

67. Theory of Plasticity for powder - sinter
forging cont ….
The effective stress can be determined from the
following relation:
According to Doraivelu et al.
(or)
for axisymmetric condition

68. Theory of Plasticity for powder - sinter
forging cont ….
 Once we know σm and σeff ,we can determine the
formability stress index (β).
 The formability stress index will tell you to what
extend the metal can be forged.
 β is constant for uniaxial compression forging and this
value is 0.33.
 For plane stress and triaxial condition, it has a range of
values.
 For hot forging, the β value is very high compared to
cold forging.

69. Theory of Plasticity for powder - sinter
forging cont ….
 According to Narayanasamy et al., the formability
strain index parameter is defined as follows:

70. Theory of Plasticity for powder - sinter
forging cont ….
 The behaviour of and are same.
 Narayanasamy et al., proposed pore closure index
parameters based on , , n, m and R value.

71. Reference
 http://www.sciencedirect.com/
 Alan Lawley and Howard A.Kuhn, “Powder Metallurgy
Processing”, Academic Press, New York.

72. References
 D. Jeyasimman, K. Sivaprasad, S. Sivasankaran, R. Ponalagusamy, R. Narayanasamy, Vijayakumar Iyer
“Microstructural observation, consolidation and mechanical behaviour of AA 6061 nanocomposites
reinforced by γ-Al2O3 nanoparticles”,Advanced Powder Technology, Volume 26, Issue 1, January 2015, Pages 139-148.
 D. Jeyasimman, R. Narayanasamy, R. Ponalagusamy, V. Anandakrishnan, M. Kamaraj, “The effects of various
reinforcements on dry sliding wear behaviour of AA 6061 nanocomposites”, Materials & Design, Volume 64,
December 2014, Pages 783-793.
 Ilangovan Arun, Muthukannan Duraiselvam, V. Senthilkumar, R. Narayanasamy, V. Anandakrishnan,“Synthesis of
electric discharge alloyed nickel–tungsten coating on tool steel and its tribological studies”,Materials &
Design, Volume 63, November 2014, Pages 257-262.
 B. Selvam, P. Marimuthu, R. Narayanasamy, V. Anandakrishnan, K.S. Tun, M. Gupta, M. Kamaraj,“Dry sliding wear
behaviour of zinc oxide reinforced magnesium matrix nano-composites”,Materials & Design, Volume 58, June
2014, Pages 475-481.
 D. Jeyasimman, S. Sivasankaran, K. Sivaprasad, R. Narayanasamy, R.S. Kambali, “An investigation of the synthesis,
consolidation and mechanical behaviour of Al 6061 nanocomposites reinforced by TiC via mechanical
alloying”,Materials & Design, Volume 57, May 2014, Pages 394-404.
 D. Jeyasimman, K. Sivaprasad, S. Sivasankaran, R. Narayanasamy, “Fabrication and consolidation behavior of Al
6061 nanocomposite powders reinforced by multi-walled carbon nanotubes”,Powder Technology, Volume 258,
May 2014, Pages 189-197.
 S.C. Vettivel, N. Selvakumar, R. Narayanasamy, N. Leema, “Numerical modelling, prediction of Cu–W nano
powder composite in dry sliding wear condition using response surface methodology”,Materials & Design,
Volume 50, September 2013, Pages 977-996.
 A.P. Mohan Raj, N. Selvakumar, R. Narayanasamy, C. Kailasanathan, “Experimental investigation on workability
and strain hardening behaviour of Fe–C–Mn sintered composites with different percentage of carbon and
manganese content”, Materials & Design, Volume 49, August 2013, Pages 791-801.

73. References cont….
 M. Srinivasan, C. Loganathan, R. Narayanasamy, V. Senthilkumar, Q.B. Nguyen, M. Gupta, “Study on hot
deformation behavior and microstructure evolution of cast-extruded AZ31B magnesium alloy and
nanocomposite using processing map”,Materials & Design, Volume 47, May 2013, Pages 449-455.
 P. Ravindran, K. Manisekar, R. Narayanasamy, P. Narayanasamy, “Tribological behaviour of powder metallurgy-
processed aluminium hybrid composites with the addition of graphite solid lubricant”, Ceramics
International, Volume 39, Issue 2, March 2013, Pages 1169-1182.
 N. Selvakumar, A.P. Mohan Raj, R. Narayanasamy, “Experimental investigation on workability and strain
hardening behaviour of Fe–C–0.5Mn sintered composites”,Materials & Design, Volume 41, October 2012, Pages
349-357.
 M. Sumathi, N. Selvakumar, R. Narayanasamy, “Workability studies on sintered Cu–10SiC preforms during cold
axial upsetting”, Materials & Design, Volume 39, August 2012, Pages 1-8.
 P. Ravindran, K. Manisekar, P. Narayanasamy, N. Selvakumar, R. Narayanasamy, “Application of factorial
techniques to study the wear of Al hybrid composites with graphite addition”, Materials & Design, Volume 39,
August 2012, Pages 42-54.
 V. Senthilkumar, A. Balaji, R. Narayanasamy, “Analysis of hot deformation behavior of Al 5083–TiC
nanocomposite using constitutive and dynamic material models”, Materials & Design, Volume 37, May 2012,
Pages 102-110.
 V.S. Sreenivasan, D. Ravindran, V. Manikandan, R. Narayanasamy, “Influence of fibre treatments on mechanical
properties of short Sansevieria cylindrica/polyester composites”, Materials & Design, Volume 37, May 2012, Pages
111-121.
 T. Vigraman, D. Ravindran, R. Narayanasamy, “Effect of phase transformation and intermetallic compounds on
the microstructure and tensile strength properties of diffusion-bonded joints between Ti–6Al–4V and AISI
304L”, Materials & Design, Volume 36, April 2012, Pages 714-727.

74. References cont….
 D.R. Kumar, R. Narayanasamy, C. Loganathan, “Effect of Glass and SiC in Aluminum matrix on workability and
strain hardening behavior of powder metallurgy hybrid composites”, Materials & Design, Volume 34, February
2012, Pages 120-136.
 M. Srinivasan, C. Loganathan, M. Kamaraj, Q.B. Nguyen, M. Gupta, R. Narayanasamy, “Sliding wear behaviour of
AZ31B magnesium alloy and nano-composite”,Transactions of Nonferrous Metals Society of China, Volume 22,
Issue 1, January 2012, Pages 60-65.
 S. Sivasankaran, K. Sivaprasad, R. Narayanasamy, “Microstructure, cold workability and strain hardening
behavior of trimodaled AA 6061–TiO2 nanocomposite prepared by mechanical alloying”, Materials Science and
Engineering: A, Volume 528, Issues 22–23, 25 August 2011, Pages 6776-6787.
 S. Sivasankaran, K. Sivaprasad, R. Narayanasamy, P.V. Satyanarayana, “X-ray peak broadening analysis of AA
6061100 − x − x wt.% Al2O3 nanocomposite prepared by mechanical alloying”, Materials Characterization,
Volume 62, Issue 7, July 2011, Pages 661-672.
 S. Sivasankaran, K. Sivaprasad, R. Narayanasamy, Vijay Kumar Iyer, “Evaluation of compaction equations and
prediction using adaptive neuro-fuzzy inference system on compressibility behavior of AA 6061100 − x–x wt.%
TiO2 nanocomposites prepared by mechanical alloying”, Powder Technology, Volume 209, Issues 1–3, 15 May 2011,
Pages 124-137.
 D.R. Kumar, C. Loganathan, R. Narayanasamy, “Effect of glass in aluminum matrix on workability and strain
hardening behavior of powder metallurgy composite”, Materials & Design, Volume 32, Issue 4, April 2011, Pages
2413-2422.
 V.S. Sreenivasan, D. Ravindran, V. Manikandan, R. Narayanasamy, “Mechanical properties of randomly oriented
short Sansevieria cylindrica fibre/polyester composites”, Materials & Design, Volume 32, Issue 4, April 2011, Pages
2444-2455.
 M. Srinivasan, C. Loganathan, V. Balasubramanian, Q.B. Nguyen, M. Gupta, R. Narayanasamy, “Feasibility of
joining AZ31B magnesium metal matrix composite by friction welding”, Materials & Design, Volume 32, Issue 3,
March 2011, Pages 1672-1676.

75. References cont….
 V.S. Sreenivasan, S. Somasundaram, D. Ravindran, V. Manikandan, R. Narayanasamy, “Microstructural, physico-
chemical and mechanical characterisation of Sansevieria cylindrica fibres – An exploratory investigation”,
Materials & Design, Volume 32, Issue 1, January 2011, Pages 453-461.
 S. Sivasankaran, K. Sivaprasad, R. Narayanasamy, Vijay Kumar Iyer, “Effect of strengthening mechanisms on cold
workability and instantaneous strain hardening behavior during grain refinement of AA 6061-10 wt.% TiO2
composite prepared by mechanical alloying”, Journal of Alloys and Compounds, Volume 507, Issue 1, 24
September 2010, Pages 236-244.
 S. Sivasankaran, K. Sivaprasad, R. Narayanasamy, Vijay Kumar Iyer, “An investigation on flowability and
compressibility of AA 6061100 − x-x wt.% TiO2 micro and nanocomposite powder prepared by blending and
mechanical alloying”, Powder Technology, Volume 201, Issue 1, 12 July 2010, Pages 70-82.
 G. Naveen Kumar, R. Narayanasamy, S. Natarajan, S.P. Kumaresh Babu, K. Sivaprasad, S. Sivasankaran, “Dry sliding
wear behaviour of AA 6351-ZrB2 in situ composite at room temperature”, Materials & Design, Volume 31, Issue 3,
March 2010, Pages 1526-1532.
 S. Sivasankaran, K. Sivaprasad, R. Narayanasamy, Vijay Kumar Iyer, “Synthesis, structure and sinterability of 6061
AA100−x–x wt.% TiO2 composites prepared by high-energy ball milling”, Journal of Alloys and Compounds,
Volume 491, Issues 1–2, 18 February 2010, Pages 712-721.
 S. Sivasankaran, R. Narayanasamy, T. Ramesh, M. Prabhakar, “Analysis of workability behavior of Al–SiC P/M
composites using backpropagation neural network model and statistical technique”, Computational Materials
Science, Volume 47, Issue 1, November 2009, Pages 46-59.
 R. Narayanasamy, V. Anandakrishnan, K.S. Pandey, “Effect of molybdenum addition on workability of powder
metallurgy steels during cold upsetting”, Materials Science and Engineering: A, Volume 517, Issues 1–2, 20 August
2009, Pages 30-36.
 S. Natarajan, R. Narayanasamy, S.P. Kumaresh Babu, G. Dinesh, B. Anil Kumar, K. Sivaprasad, “Sliding wear
behaviour of Al 6063/TiB2 in situ composites at elevated temperatures”,Materials & Design, Volume 30, Issue 7,
August 2009, Pages 2521-2531.

76. References cont….
 R. Narayanasamy, T. Ramesh, M. Prabhakar, “Effect of particle size of SiC in aluminium matrix on workability
and strain hardening behaviour of P/M composite”, Materials Science and Engineering: A, Volume 504, Issues 1–2,
25 March 2009, Pages 13-23.
 K. Sivaprasad, S. P. Kumaresh Babu, S. Natarajan, R. Narayanasamy, B. Anil Kumar, G. Dinesh, “Study on abrasive
and erosive wear behaviour of Al 6063/TiB2 in situ composites”, Materials Science and Engineering: A, Volume
498, Issues 1–2, 20 December 2008, Pages 495-500.
 R. Narayanasamy, V. Anandakrishnan, K.S. Pandey, “Effect of carbon content on instantaneous strain-hardening
behaviour of powder metallurgy steels”, Materials Science and Engineering: A, Volume 497, Issues 1–2, 15
December 2008, Pages 505-511.
 R. Narayanasamy, V. Anandakrishnan, K.S. Pandey, “Comparison of workability strain and stress parameters of
powder metallurgy steels AISI 9840 and AISI 9845 during cold upsetting”, Materials & Design, Volume 29, Issue
10, December 2008, Pages 1919-1925.
 R. Narayanasamy, K. Baskaran, S. Arunachalam, D. Murali Krishna, “An experimental investigation on barreling
of aluminium alloy billets during extrusion forging using different lubricants”, Materials & Design, Volume 29,
Issue 10, December 2008, Pages 2076-2088.
 K. Baskaran, R. Narayanasamy, “Effect of various stress ratio parameters on cold upset forging of irregular
shaped billets using graphite as lubricant under plane and triaxial stress state conditions” Materials & Design,
Volume 29, Issue 10, December 2008, Pages 2089-2103.
 R. Narayanasamy, V. Anandakrishnan, K.S. Pandey, “Effect of carbon content on workability of powder
metallurgy steels”, Materials Science and Engineering: A, Volume 494, Issues 1–2, 25 October 2008, Pages 337-342.
 A.Rajeshkannan, K.S. Pandey, S. Shanmugam, R. Narayanasamy, “Deformation behaviour of sintered high
carbon alloy powder metallurgy steel in powder preform forging”, Materials & Design, Volume 29, Issue 9,
October 2008, Pages 1862-1867.

77. References cont….
 R. Ponalagusamy, R. Narayanasamy, “Finite difference method for analysis of open-die forging of sintered
cylindrical billets”, Materials & Design, Volume 29, Issue 9, October 2008, Pages 1886-1892.
 A Rajeshkannan, K S Pandey, S Shanmugam, R Narayanasamy, “Sintered Fe-0.8%C-1. 0%Si-0.4%Cu P/M Steel
Preform Behaviour During Cold Upsetting”, Journal of Iron and Steel Research, International, Volume 15, Issue 5,
September 2008, Pages 81-87.
 R. Narayanasamy, V. Anandakrishnan, K.S. Pandey, “Effect of geometric work-hardening and matrix work-
hardening on workability and densification of aluminium–3.5% alumina composite during cold
upsetting”,Materials & Design, Volume 29, Issue 8, 2008, Pages 1582-1599.
 R. Narayanasamy, K. Baskaran, D. Muralikrishna, “Some studies on stresses and strains of aluminium alloy
during extrusion-forging at room temperature”, Materials & Design, Volume 29, Issue 8, 2008, Pages 1623-1632.
 R. Narayanasamy, V. Senthilkumar, K.S. Pandey, “Some features on hot forging of powder metallurgy sintered
high strength 4%titanium carbide composite steel preforms under different stress state conditions”, Materials
& Design, Volume 29, Issue 7, 2008, Pages 1380-1400.
 R. Narayanasamy, T. Ramesh, K.S. Pandey, “Some aspects on cold forging of aluminium–alumina powder
metallurgy composite under triaxial stress state condition”, Materials & Design, Volume 29, Issue 6, 2008, Pages
1212-1227.
 R. Ponalagusamy, R. Narayanasamy, R. Venkatesan, S. Senthilkumar,“Computer-aided metal flow investigation
in streamlined extrusion dies”, Materials & Design, Volume 29, Issue 6, 2008, Pages 1228-1239.
 K. Baskaran, R. Narayanasamy, “An experimental investigation on work hardening behaviour of elliptical
shaped billets of aluminium during cold upsetting”, Materials & Design, Volume 29, Issue 6, 2008, Pages 1240-
1265.

78. References cont….
 R. Narayanasamy, T. Ramesh, K.S. Pandey, S.K. Pandey, “Effect of particle size on new constitutive relationship
of aluminium–iron powder metallurgy composite during cold upsetting”,Materials & Design, Volume 29, Issue
5, 2008, Pages 1011-1026.
 A. Syed Abu Thaheer, R. Narayanasamy, “Comparison of barreling in lubricated truncated cone billets during
cold upset forging of various metals”,Materials & Design, Volume 29, Issue 5, 2008, Pages 1027-1035.
 R. Narayanasamy, T. Ramesh, K.S. Pandey, “Some aspects on cold forging of aluminium–iron powder
metallurgy composite under triaxial stress state condition”, Materials & Design, Volume 29, Issue 4, 2008, Pages
891-903.
 K. Baskaran, R. Narayanasamy, “Some aspects of barrelling in elliptical shaped billets of aluminium during
cold upset forging with lubricant”, Materials & Design, Volume 29, Issue 3, 2008, Pages 638-661.
 R. Narayanasamy, V. Senthilkumar, K.S. Pandey, “Effect of titanium carbide particle addition on the
densification behavior of sintered P/M high strength steel preforms during cold upset forming”, Materials
Science and Engineering: A, Volume 456, Issues 1–2, 15 May 2007, Pages 180-188.
 R. Narayanasamy, T. Ramesh, K.S. Pandey, “An experimental investigation on strain hardening behaviour of
aluminium – 3.5% alumina powder metallurgy composite preform under various stress states during cold
upset forming”, Materials & Design, Volume 28, Issue 4, 2007, Pages 1211-1223.
 R. Narayanasamy, N. Selvakumar, K.S. Pandey, “Phenomenon of instantaneous strain hardening behaviour of
sintered Al–Fe composite preforms during cold axial forming”, Materials & Design, Volume 28, Issue 4, 2007,
Pages 1358-1363.
 S. Malayappan, R. Narayanasamy, G. Esakkimuthu, “Barrelling of aluminium solid cylinders during cold upset
forging with constraint at both ends”, Materials & Design, Volume 28, Issue 4, 2007, Pages 1404-1411.

79. References cont….
 R. Narayanasamy, C. Loganathan, “The influence of friction on the prediction of wrinkling of prestrained
blanks when drawing through a conical die”, Materials & Design, Volume 28, Issue 3, 2007, Pages 904-912.
 S. Malayappan, R. Narayanasamy, K. Kalidasamurugavel, “A study on barrelling behaviour of aluminium billets
during cold upsetting with an extrusion die constraint at one end”, Materials & Design, Volume 28, Issue 3, 2007,
Pages 954-961.
 A. Syed Abu Thaheer, R. Narayanasamy, “Barrelling in truncated lubricated zinc cone billets during cold upset
forging”, Materials & Design, Volume 28, Issue 2, 2007, Pages 434-440.
 K. Manisekar, R. Narayanasamy, “Effect of friction on barrelling in square and rectangular billets of
aluminium during cold upset forging”, Materials & Design, Volume 28, Issue 2, 2007, Pages 592-598.
 N. Selvakumar, P. Ganesan, P. Radha, R. Narayanasamy, K.S. Pandey, “Modelling the effect of particle size and
iron content on forming of Al–Fe composite preforms using neural network”, Materials & Design, Volume 28,
Issue 1, 2007, Pages 119-130.
 R. Narayanasamy, V. Senthilkumar, K.S. Pandey, “Some aspects of workability studies on hot forging of sintered
high strength 4% titanium carbide composite steel performs”, Materials Science and Engineering: A, Volume 425,
Issues 1–2, 15 June 2006, Pages 121-130.
 R. Narayanasamy, V. Senthilkumar, K.S. Pandey, “Some aspects on hot forging features of P/M sintered iron
preforms under various stress state conditions”, Mechanics of Materials, Volume 38, Issue 4, April 2006, Pages
367-386.
 R. Narayanasamy, T. Ramesh, K.S. Pandey, “Some aspects on strain hardening behaviour in three dimensions
of aluminium–iron powder metallurgy composite during cold upsetting”, Materials & Design, Volume 27, Issue
8, 2006, Pages 640-650.

80. References cont….
 R. Narayanasamy, T. Ramesh, K.S. Pandey, “Workability studies on cold upsetting of Al–Al2O3 composite
material”, Materials & Design, Volume 27, Issue 7, 2006, Pages 566-575.
 R. Narayanasamy, R. Ponalagusamy, R. Venkatesan, P. Srinivasan, “An upper bound solution to extrusion of
circular billet to circular shape through cosine dies”, Materials & Design, Volume 27, Issue 5, 2006, Pages 411-415.
 K. Manisekar, R. Narayanasamy, S. Malayappan, “Effect of friction on barrelling in square billets of aluminium
during cold upset forging”, Materials & Design, Volume 27, Issue 2, 2006, Pages 147-155.
 R. Ponalagusamy, R. Narayanasamy, P. Srinivasan, “Design and development of streamlined extrusion dies a
Bezier curve approach”, Journal of Materials Processing Technology, Volume 161, Issue 3, 30 April 2005, Pages 375-
380.
 R. Narayanasamy, T. Ramesh, K.S. Pandey , “An investigation on instantaneous strain hardening behaviour in
three dimensions of aluminium–iron composites during cold upsetting”, Materials Science and Engineering: A,
Volume 394, Issues 1–2, 15 March 2005, Pages 149-160.
 R. Narayanasamy, T. Ramesh, K.S. Pandey, “Some aspects on workability of aluminium–iron powder
metallurgy composite during cold upsetting”, Materials Science and Engineering: A, Volume 391, Issues 1–2, 25
January 2005, Pages 418-426.
 N Selvakumar, R Narayanasamy, “Phenomenon of strain hardening behaviour of sintered aluminium
preforms during cold axial forming”, Journal of Materials Processing Technology, Volume 142, Issue 2, 25 November
2003, Pages 347-354.
 R Narayanasamy, P Srinivasan, R Venkatesan, “Computer aided design and manufacture of streamlined
extrusion dies”, Journal of Materials Processing Technology, Volume 138, Issues 1–3, 20 July 2003, Pages 262-264.

81. References cont….
 S. Malayappan, R. Narayanasamy, “Some aspects on barrelling in aluminium solid cylinders during cold upset
forging using a die with constraints”, Journal of Materials Processing Technology, Volume 135, Issue 1, 1 April 2003,
Pages 18-29.
 R. Narayanasamy, R. Ponalagusamy, K.R. Subramanian, “Generalised yield criteria of porous sintered powder
metallurgy metals”, Journal of Materials Processing Technology, Volume 110, Issue 2, 19 March 2001, Pages 182-185.
 R Narayanasamy, S Sathiyanarayanan, R Ponalagusamy, “Uniaxial tensile behaviour of ZM-21 magnesium alloy at
room temperature”, Journal of Materials Processing Technology, Volume 102, Issues 1–3, 15 May 2000, Pages 56-58.
 R Narayanasamy, S Sathiyanarayanan, R Ponalagusamy, “A study on barrelling in magnesium alloy solid
cylinders during cold upset forming”, Journal of Materials Processing Technology, Volume 101, Issues 1–3, 14 April
2000, Pages 64-69.
 R Narayanasamy, K.S Pandey, “A study on the barrelling of sintered iron preforms during hot upset forging”,
Journal of Materials Processing Technology, Volume 100, Issues 1–3, 3 April 2000, Pages 87-94.
 R. Narayanasamy, R. Ponalagusamy, “A mathematical theory of plasticity for compressible powder metallurgy
materials — Part III”, Journal of Materials Processing Technology, Volume 100, Issues 1–3, 3 April 2000, Pages 262-
265.
 R Narayanasamy, R Ponalagusamy, “A mathematical theory of plasticity for the upsetting of compressible P/M
materials”, Journal of Materials Processing Technology, Volume 97, Issues 1–3, 1 January 2000, Pages 107-109.
 R. Narayanasamy, R. Ponalagusamy, “A mathematical theory of plasticity for compressible powder metallurgy
materials — Part II”, Journal of Materials Processing Technology, Volume 97, Issues 1–3, 1 January 2000, Pages 110-113.

82. References cont….
 R. Narayanasamy, R. Ponalagusamy, “A mathematical theory of plasticity for compressible P/M
materials”, Journal of Materials Processing Technology, Volume 86, Issues 1–3, 15 February 1999,
Pages 159-162.
 R Narayanasamy, KS Pandey, “Some aspects of work hardening in sintered aluminium–iron
composite preforms during cold axial forming”, Journal of Materials Processing Technology,
Volume 84, Issues 1–3, 1 December 1998, Pages 136-142.
 A.J.R. Inigoraj, R. Narayanasamy, K.S. Pandey, “Strain-hardening behaviour in sintered
aluminium–3.5% alumina composite preforms during axial compression with and without
annealing”, Journal of Materials Processing Technology, Volume 84, Issues 1–3, 1 December 1998,
Pages 143-148.
 R. Narayanasamy, K.S. Pandey, “Salient features in the cold upset-forming of sintered
aluminium–3.5% alumina powder composite performs”, Journal of Materials Processing
Technology, Volume 72, Issue 2, 7 December 1997, Pages 201-207.
 R. Narayanasamy, K.S. Pandey, “Phenomenon of barrelling in aluminium solid cylinders
during cold upset-forming”, Journal of Materials Processing Technology, Volume 70, Issues 1–3,
October 1997, Pages 17-21.
 R. Narayanasamy, R.S.N. Murthy, K. Viswanatham, G.R. Chary, “Prediction of the barreling of
solid cylinders under uniaxial compressive load”, Journal of Mechanical Working Technology,
Volume 16, Issue 1, February 1988, Pages 21-30.
 Role of hybrid reinforcement on microstructural observation, characterization and
consolidation behavior of AA 6061 nanocomposite, Advanced Powder Technology, Article in
Press (2015).

83. Thank you