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Electroconsolidation{reg_sign} is a proprietary process for rapid, pressure-assisted densification of powder preforms. The parts to be consolidated are placed within a bed of free-flowing powder, and pressure is applied by rams that act on the powder medium. Heat for consolidation is generated internally by electrical resistive heating of the medium while it is in direct contact with the preform(s). A mathematical model has been developed to predict the temperature profiles within the Electroconsolidation die during operation. Numerical simulation is performed by coupling a three-dimensional (3-D) finite-element electromagnetic field program (ELEKTRA) and a 3-D finite-difference materials process simulator (MaPS) to incorporate the effects of pressure and electrical fields on heat transfer and temperature variation within the die during heating and cooling. The methods used in developing the model are presented. Use of the model minimizes the experiments needed to design and evaluate commercial applications of Electroconsolidation

User guide for modeling of electroconsolidation process with ELEKTRA and MaPS codes.