Accurate impact energy control is important for the success of the powder-forged (P/F) technique. This paper address how impact energy influences the densification and mechanical properties of powder metallurgical (P/M) preforms during a P/F process by combining finite element simulations and experiments. The simulated results coincide well with the experimental results. Results reveal that impact energy strongly influences the P/M preform densification by controlling their stress states and strain rate. The densification continuously proceeds throughout the P/F processing by the three steps of micro-pore compression, segmentation, and closure, while the densification uniformity gradually deteriorates in the earlier free upsetting step and then significantly improves in the later closed compressing step. The increased impact energy within the range below 56.3 J/cm³ induces a higher strain rate, and thus facilitates the P/M preform densification notably. Inversely, the excessive impact energy not only has less influence on the densification but also creates exceptionally high forging pressure. The notably increased density improves the mechanical properties of the P/F forgings significantly; meanwhile, the concomitant work hardening changes their tensile fracture modes and slows down their ductility rising. In this study, the P/F Fe-C-Cu forgings prepared at the optimized impact energy of 56.3 J/cm³ have a high and uniform density and good mechanical properties. This study can provide theoretical guidance for the rational process design of powder forging.

精确的冲击能量控制对于粉末锻造（P / F）技术的成功至关重要。本文结合有限元模拟和实验，探讨了冲击能量如何在粉末冶金过程中影响粉末冶金（P / M）瓶坯的致密化和机械性能。仿真结果与实验结果吻合良好。结果表明，冲击能通过控制应力状态和应变速率，极大地影响了P / M瓶坯的致密化。在整个P / F处理过程中，通过微孔压缩，分段和封闭这三个步骤，致密化持续进行，而致密化均匀性在较早的自由setting粗步骤中逐渐变差，然后在较晚的闭紧压缩步骤中显着改善。³引起较高的应变率，因此显着促进了P / M预型件的致密化。相反，过大的冲击能量不仅对致密化的影响较小，而且还会产生极高的锻造压力。密度的显着提高大大改善了P / F锻件的机械性能；同时，伴随的工作硬化改变了它们的拉伸断裂模式并减缓了它们的延展性上升。在这项研究中，以56.3 J / cm ³的最佳冲击能制备的P / F Fe-C-Cu锻件具有高且均匀的密度和良好的机械性能。该研究可以为粉末锻造的合理工艺设计提供理论指导。