Consolidation and green body characteristics of gelcast metallic powder

A preliminary study concerning the compaction of metallic powder was carried out in order to investigate a rarely explored route in powder metallurgy, to form complex geometry parts, known as gelcasting. Green bodies produced with as supplied stainless steel powder showed a tendency to form foam, which affected the surface finishing. The mechanical behaviour of green compacts was also affected by the processing additives present in the metallic powder. Organics in the as supplied powder were removed by thermal treatment at 500 degrees C and additional samples were produced. Although no difference in green density was observed, these samples displayed better surface finish and mechanical characteristics, as a result of improved adhesion between the polymer network and particle surface. The results showed that the gelcasting process is able to produce green parts suitable for subsequent thermal treatment.