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Further experiments and modeling for microscale compression molding of metals at elevated temperatures

Published online by Cambridge University Press:  31 January 2011

J. Jiang
Department of Mechanical Engineering, Louisiana State University, Baton Rouge, Louisiana 70803
W.J. Meng*
Department of Mechanical Engineering, Louisiana State University, Baton Rouge, Louisiana 70803
G.B. Sinclair
Department of Mechanical Engineering, Louisiana State University, Baton Rouge, Louisiana 70803
E. Lara-Curzio
High Temperature Materials Laboratory, Oak Ridge National Laboratory, Oak Ridge, Tennessee 37831
a)Address all correspondence to this author. e-mail:
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Replication of metallic high-aspect-ratio microscale structures (HARMS) by compression molding has been demonstrated recently. Molding replication of metallic HARMS can potentially lead to low-cost fabrication of a wide variety of metal-based microdevices. Understanding the mechanics of metal micromolding is critical for assessing the capabilities and limitations of this replication technique. This paper presents results of instrumented micromolding of Al. Measured molding response was rationalized with companion high-temperature tensile testing of Al using a simple mechanics model of the micromolding process. The present results suggest that resisting pressure on the mold insert during micromolding is governed primarily by the yield stress of the molded metal at the molding temperature and a frictional traction on the sides of the insert. The influence of strain rate is also considered.

Copyright © Materials Research Society 2007

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