Electro Sinter Forging (ESF) is a powder metallurgical method to rapidly produce a wide range of materials and components. Loose binder-less powders are inserted in the automatic dosing system or manually inserted in the mold. The automatic procedure applies a pre-pressure onto the powders to guarantee electrical contact hence it superimposes an intense electromagnetic pulse with a mechanical pulse. The two pulses last 30 to 100 ms and, after a brief holding time, the sintered component is extracted by the lower plunger and pushed out by the extractor to leave room for the next sintering.
By properly choosing the processing parameters either fully dense (>97% of theoretical density) or porous materials (down to 40% of theoretical density) can be obtained with consistent properties. The electro sinter forged objects have tight dimensional tolerances of ±0.04 mm (±1.5 mil) in the pressing direction and as small as ±0.02 mm (±0.8 mil) in direction perpendicular to the pressing action.
One realization of our sintering process is given by a capacitor discharge apparatus combined with a high speed press. The electrical power circuit is constituted by two mutually induction coupled power circuit:
On standard machines the secondary circuit can reach a maximum voltage
Built to work in complete autonomy, ESF machines are intrinsically safe, with little maintenance and low complexity: