FEM Analysis on Thermo-mechanical behavior and experimental validation of Al20Cr20Fe25Ni25Mn10 High Entropy Alloy during Spark Plasma Sintering

Abstract

High entropy alloy developed with spark plasma sintering was modelled with COMSOL Multiphysics. This focus at examining the effect of spark plasma sintering fabrication parameters on thermal and mechanical stress distribution in the sintered Al20Cr20Fe25Ni25Mn10 high entropy alloy (HEA). And to achieve this, a fully thermal-electrical-mechanical integrated and dynamic finite element model (FEM) was adopted. The simulation utilised the optimal parameters employed in the laboratory to produce the samples. The geometry for the modelling was 2D axisymmetric as the parameters were based on temperature-dependent characteristics noting that only the sintered sample was modelled and simulated in order not to simplify the modelling. The FEM maintained constant sintering temperature, pressure, and heating rate but concentrated on the impact of residence durations. To verify the simulation results, morphological alterations and densification validation tests were conducted. The microstructural characterization of the sintered sample demonstrated the relationship between the stress distribution and computational temperature found in the current FEM. Noting good particle-to-particle necking. From the model, results showed that the sintered sample at different points depicted a yield stress far greater than the von Mises stress with least thermal stress at 30 MPa. This validate that the developed sample is mechanically stable based on the factor of safety failure criterion and design. However, the study recommend that further work should be conducted considering different sintering pressure of variation 10 to 30 MPa.