Volume 106
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Discrete element analysis of rotational centrifugal method for enhanced powder packing densification in a pre-HIP capsule
Wenqing Tian a b, Runyu Yang b, Chao Cai a *, Yusheng Shi a
a State Key Laboratory of Material Processing and Die & Mould Technology and School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
b School of Materials Science and Engineering, University of New South Wales, Sydney, 2052, Australia
10.1016/j.partic.2025.09.002
Volume 106, November 2025, Pages 99-109
Received 27 July 2025, Revised 27 August 2025, Accepted 3 September 2025, Available online 5 September 2025, Version of Record 11 September 2025.
E-mail: chaocai@hust.edu.cn

Highlights

• Rotational centrifugal method effectively addresses low-density regions in a complex HIP capsule.

• DEM simulations revealed particle motion and void elimination mechanisms.

• Systematic comparison of three dynamic packing densification techniques for Ti-6Al-4V powders.


Abstract

Hot isostatic pressing (HIP) is a critical powder metallurgy technique for manufacturing high-performance components. However, achieving uniform powder distribution within complex capsules is challenging, particularly in critical low-density regions where inadequate powder filling leads to non-uniform deformation and potential part rejection after HIP. This study investigated the powder filling and packing densification behavior of Ti-6Al-4V particles through discrete element method (DEM) simulations to develop an enhanced densification technique targeting these critical regions. A new rotational centrifugal method was proposed to address this challenge. Results demonstrated that vertical vibration achieved limited improvement, and horizontal vibration exhibited non-uniform powder distribution. The proposed rotational centrifugal method at 200 rpm proved most effective, achieving the highest relative density with superior uniformity and rapid densification. The analysis in rotational motion revealed that rapid densification originates from consistent centrifugal forces. Upon stopping rotation, particles undergo localized vigorous motion, resulting in a slight decrease in relative density. To address this, an optimized deceleration scheme was developed. It achieved a relative density of 0.549, representing improvements of 70.5 % over vertical vibration and 4.2 % over horizontal vibration. These findings provide valuable insights for optimizing pre-HIP processing parameters for complex components, offering a promising solution for addressing powder filling challenges.

Graphical abstract
Keywords
Hot isostatic pressing; Discrete element method; Packing densification; Rotational centrifugal method