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<p>Powder metallurgy (PM) enables the production of complex components from metallic powders; however, developing a cost-efficient fabrication route for PM dies remains a persistent industrial challenge. This study introduces a novel die fabrication strategy based on an epoxy–aluminum (Al) powder composite. The composite was formulated by blending Al powder into epoxy resin at controlled weight fractions, producing a material with the requisite strength and wear resistance for PM applications. Among the tested formulations, a mixture comprising 174 epoxy resin with 60 wt.% Al powder, cured at 125&#xa0;°C for 3&#xa0;h, exhibited the most favorable performance, delivering enhanced mechanical properties and reduced wear rates. The resulting PM die was successfully employed to mold graphite powder into green compacts, which displayed higher compressive strength and superior surface finish compared to parts produced using commercial rapid tooling materials. Under experimental conditions, the die achieved a service life of approximately 30 molding cycles. This approach reduces material costs by up to 85% relative to conventional commercial rapid tooling, underscoring its promise for scalable and economically viable PM die manufacturing.</p>

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Accelerated fabrication of powder metallurgy dies via a cost-efficient engineering strategy

  • 期刊论文

  • 发表日期：

    2025年9月8日

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  • Chil-Chyuan Kuo,
  • Cheng-Xuan Tasi,
  • Armaan Farooqui,
  • Song-Hua Huang

摘要

Powder metallurgy (PM) enables the production of complex components from metallic powders; however, developing a cost-efficient fabrication route for PM dies remains a persistent industrial challenge. This study introduces a novel die fabrication strategy based on an epoxy–aluminum (Al) powder composite. The composite was formulated by blending Al powder into epoxy resin at controlled weight fractions, producing a material with the requisite strength and wear resistance for PM applications. Among the tested formulations, a mixture comprising 174 epoxy resin with 60 wt.% Al powder, cured at 125 °C for 3 h, exhibited the most favorable performance, delivering enhanced mechanical properties and reduced wear rates. The resulting PM die was successfully employed to mold graphite powder into green compacts, which displayed higher compressive strength and superior surface finish compared to parts produced using commercial rapid tooling materials. Under experimental conditions, the die achieved a service life of approximately 30 molding cycles. This approach reduces material costs by up to 85% relative to conventional commercial rapid tooling, underscoring its promise for scalable and economically viable PM die manufacturing.