Bambang Suharno, Mahruri Arif Wicaksono, Widi Astuti, M. Akbar Rhamdhani
This study presents a comprehensive for finite element study on the modeling, simulation, and optimization of thermo-mechanical particle collision and bonding under thermal loading in electrode fabrication. The thermal model was developed to evaluate heat propagation generated by a 3000-W zero voltage switching (ZVS) induction heater, applied to particles with initial temperatures of 300°C, 400°C, and 500°C. Numerical simulations were conducted to capture transient heat distribution and to validate the model against experimental measurements. At an initial temperature of 300°C, the simulation results after 45 s demonstrated strong agreement with experimental data, with relative errors ranging from 1.40% to 14.09%. Similar accuracy trends were observed at 400°C and 500°C, confirming the robustness and reliability of the developed thermal model in predicting heat transfer behavior under varying thermal conditions. Following thermal validation, a coupled thermo-mechanical analysis was performed using ANSYS Explicit Dynamic to investigate particle collision dynamics and bonding mechanisms. The simulations focused on collision-induced deformation, stress evolution, and interfacial interaction between particles under varying impact velocities. The results revealed that particle overlap, ranging from 0 to 1.553 µm, is significantly influenced by kinetic energy, where increasing impact velocity leads to enhanced plastic deformation and improved particle consolidation. Distinct deformation regimes were identified: elastic behavior at velocities of 50–200 m/s, localized plastic deformation at 300–400 m/s, and optimal bonding conditions at 500 m/s. At this highest velocity, the system exhibited maximum equivalent stress of 656.69 MPa, indicating favorable conditions for interparticle bonding and homogenization. Furthermore, the framework enables process optimization by correlating thermal input and impact velocity with bonding efficiency and material response. The integration of validated thermal modeling with explicit dynamic simulation provides a predictive tool for designing heat-assisted particle processing systems, offering improved control over microstructural evolution and bonding quality. Overall, this study contributes to the advancement of thermo-mechanical modeling approaches for particle-based manufacturing processes and supports the development of optimized processing parameters for enhanced material performance. © The Minerals, Metals & Materials Society 2026.
Department of Metallurgical and Materials Engineering, Faculty of Engineering, University of Indonesia, Depok City, 16425, Indonesia; Industrial Engineering Study Program, Faculty of Industrial Technology, Sumatera Institute of Technology, Terusan Ryacudu Street, South Lampung, Bandar Lampung, 35365, Indonesia; Research Center of Mineral Technology, National Research and Innovation Agency, Lampung, Tanjung Bintang, 35361, Indonesia; Department of Mechanical and Product Design Engineering, Fluid and Process Dynamics Research Group, Swinburne University of Technology, Melbourne, 3122, VIC, Australia