In an attempt to achieve maximum densification and minimum distortion for near-net-shaped manufacturing of powder-based components, the process of quasi-isostatic pressing (QIP) is studied. In QIP, the self-propagating high-temperature synthesis (SHS) and the subsequent consolidation are carried out in a rigid die where a powder body subjected to SHS is surrounded by a granular pressure-transmitting medium (PTM), Following the SHS, a uniaxial load is applied to the PTM, which builds up a quasi-isostatic stress in the die. The constitutive behaviors of both the post-SHS body and the PTM are determined based on theoretical and experimental studies. The densification and shape distortion of a post-SHS powder specimen are simulated using a finite element model and the results are compared to the experimental data with satisfactory agreement. To obtain the desired final shape, the optimized initial shape of the pre-QIP porous body is determined based on a special iterative simulation approach.
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