Process performance and characterization of microwave hybrid and conventional sintering methods on iron/silicon carbide

Microwave sintering has become one of the well-known sintering processing methods used by researchers to replace the conventional sintering process. The use of microwave for sintering in powder metallurgy has promoted cost reduction and energy savings for the industries. Microwave sintering has also been studied to sinter various kinds of Metal Matrix Composites (MMCs). The latest technology had combined microwave and conventional sintering into microwave hybrid sintering. In this research, the use of microwave hybrid sintering has been studied in terms of its viability to sinter the metal matrix composite of iron and silicon carbide (Fe/SiC). Comparison of the sintering processes and performance, physical (relative density, shrinkage and microstructure) and mechanical (tensile strength and hardness) properties of Fe/SiC were made for the samples sintered by both sintering processes. In order to determine the relative density and the shrinkage, the direct measurements were taken using Vernier caliper while for microstructure analysis, the morphology tests were conducted using Field Emission Scanning Electron Microscope (FESEM). For physical properties, the Brazillian Disc Test was conducted to analyze the tensile strength and Rockwell Hardness Tester was used to analyze the hardness. Three different compositions of Fe/SiC which are pure Fe, Fe-10SiC and Fe-20SiC were studied. The sintering temperatures used for both sintering processes were fixed at 1000 oC, 1050 oC, 1100 oC and 1200 oC with a heating rate of 10 oC/min and soaking time of 45 minutes in argon atmosphere. Fe-10SiC and Fe-20SiC were found damaged when sintered using microwave hybrid sintering at temperature above 1050 oC. The overall results show that Fe/SiC sintered by microwave hybrid had a faster sintering time compared to conventional sintering and the best sintering temperature to sinter Fe/SiC using microwave hybrid sintering was 1000 oC. In addition, the results also show that relatively higher shrinkage and swelling occurred for samples sintered under microwave hybrid process. The addition of SiC led to the decrease in the relative densities of the sintered Fe/SiC samples. The tensile strength of the Fe/SiC samples decreased with the increased in the SiC content. Microwave hybrid sintering produced samples with relatively higher tensile strength values, especially for pure Fe and for 10 wt. % added SiC at 1050⁰C sintering temperature different compositions of Fe/SiC which are pure Fe, Fe-10SiC and Fe-20SiC were studied. The sintering temperatures used for both sintering processes were fixed at 1000 oC, 1050 oC, 1100 oC and 1200 oC with a heating rate of 10 oC/min and soaking time of 45 minutes in argon atmosphere. Fe-10SiC and Fe-20SiC were found damaged when sintered using microwave hybrid sintering at temperature above 1050 oC. The overall results show that Fe/SiC sintered by microwave hybrid had a faster sintering time compared to conventional sintering and the best sintering temperature to sinter Fe/SiC using microwave hybrid sintering was 1000 oC. In addition, the results also show that relatively higher shrinkage and swelling occurred for samples sintered under microwave hybrid process. The addition of SiC led to the decrease in the relative densities of the sintered Fe/SiC samples. The tensile strength of the Fe/SiC samples decreased with the increased in the SiC content. Microwave hybrid sintering produced samples with relatively higher tensile strength values, especially for pure Fe and for 10 wt. % added SiC at 1050⁰C sintering temperature.

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