How can I design a die for my powder sample?

From your description, you need to compact your powder samples into a cylindrical shape with a hollow centre. This process involves a technique known as powder pressing or compaction.

You will likely need a custom die and punch set to shape your alloy powders. The die and punches are usually made of hardened steel to withstand the pressures of compacting powder.

Below are some general steps to design your die and form your powder sample:

Designing Your Die Set: The die set consists of the die, which forms the external shape, and one or two punches, which form the internal shape (the hollow centre). You will need to design a cylindrical die with a 7mm diameter. You'll also need two punches: one with a 3.05mm diameter to create the hollow centre, and another with a 7mm diameter to compact the powder against the die wall.

Powder Compaction Process: a. Filling the Die: Fill the die with your alloy powder. The amount of powder needed will depend on the powder's density and your sample's desired thickness. It might require some experimentation to find the right amount. b. First Compaction: Insert the smaller punch (3.05mm diameter) into the die and compact the powder using a hydraulic or mechanical press. This creates the hollow centre of your sample. c. Second Compaction: Remove the smaller punch, leaving a hollow cylindrical powder shape in the die. Now insert the larger punch (7mm diameter) into the die and compact the powder again. This shapes the powder into a solid ring with your desired dimensions.d. Ejection: After compaction, the formed part (compact) has to be ejected from the die. You might need a third, ejector punch to accomplish this.

Sintering: If your compact isn't sturdy enough for your needs, you can use a process called sintering to increase its strength. This involves heating the compact in a controlled atmosphere to a temperature below the melting point of your alloy. The heat causes the particles to bond together, increasing the strength of your sample.

Please note that designing and making a custom die set can be complex and might require the services of a professional machinist or company specialising in this type of work. Also, the compaction and sintering process can be sensitive to many variables, like powder particle size, compaction pressure, and sintering temperature, so it might take some trial and error to get your samples to come out the way you want.

Finally, to measure microwave absorption, you may need to do additional sample preparation, like polishing, to ensure a smooth surface. Then, you can place the sample in your microwave test setup for measurement.

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