The aim is to optimise the consolidation of elemental aluminium powder particles by analysing the effect of different powder sizes on apparent density of powders, density of cold compacted samples and density of ECAP samples. Three different sizes (<45μm, 75-105μm, >150μm) of aluminium powders were conventionally compacted at room temperature (400MPa) for comparison and consolidated in a single pass of ECAP at 200°C (400MPa). Grain size distributions show a significant shift to more refined grain sizes following a single pass of ECAP and better bonding of powder particles. The medium and coarse powder particles achieved the highest density but the fine powder particles showed the smallest grain sizes and highest hardness values.
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