Experimental comparison of microstructure and surface properties of Al / Al2O3 sample produced by powder metallurgy and spark plasma sintering methods

Due to the high importance of manufacturing methods with metal powders such as aluminum, in this study, using pure aluminum powder, samples were made by two methods of powder metallurgy and spark plasma sintering, and then the samples in terms of microstructure, hardness. Abrasion resistance and corrosion resistance were evaluated. Spark plasma sintering method compared to powder metallurgy method shows significant improvement in hardness, microstructure density, increased wear resistance, and corrosion of aluminum. This improvement can be attributed to the high speed and temperature of the sintering process as well as the simultaneous application of force and temperature, resulting in a more complete density of the structure. The coefficient of wear and hardness increased from 0.9 and 43 Brinell in powder metallurgy method to 0.8 and 49.3 Brinell in spark plasma sintering method, respectively. Also, according to the results of corrosion test, the linear corrosion resistance of sintering-plasma-spark sample is higher than powder metallurgy sample.