The modeling of powder compaction process, such as spark plasma sintering (SPS), requires the determination of the visco-plastic deformation behavior of the particle material including the viscosity moduli. The establishment of these parameters usually entails a long and difficult experimental campaign which in particular involves several hot isostatic pressing tests. A more straightforward method based on the coupled sinter-forging and die compaction tests, which can be easily carried out in a regular SPS device, is presented. Compared to classical creep mechanism studies, this comprehensive experimental approach can reveal the in situ porous structure morphology influence on the sintering process.
The present work reports the role of different atomic mobility induced localized pore evolution on densification during spark plasma sintering of nanocrystalline W-Mo alloy powder. The shrinkage (or expansion) behavior of cold compacted milled powders was studied using dilatometry during non-isothermal sintering up to 1600 °C. Subsequently, the milled powders were densified to ~95% relative density using spark plasma sintering up to 1600 °C. The enhanced localized Joule heating due to dynamically evolved porous structure could be attributed for the densification during spark plasma sintering.
The present work reports the effect of Ta on densification and microstructure evolution during non-isothermal and spark plasma sintering of nanocrystalline W. Nanocrystalline W-5wt.%Ta alloy powder was synthesized using mechanical alloying. The nanocrystalline powder was characterized thoroughly using X-ray diffraction line profile analysis. Furthermore, the shrinkage behavior of nanocrystalline powder was investigated during non-isothermal sintering using dilatometry. Subsequently, the alloy powder was consolidated using spark plasma sintering up to 1600 °C. The role of Ta on stabilizing the …
Herein, we demonstrate that BiCuSeO compound can be formed in bulk directly from the raw materials through reactive spark plasma sintering (RSPS) followed by ball milling and a second short spark plasma sintering step. Compared to BiCuSeO samples obtained by a conventional solid-state reaction, the electrical transport properties of the RSPS bulk were moderately affected by the sintering technique, while the lattice thermal conductivity was almost unaffected, and the figure of merit zT attained a value at 773 K comparable to state-of-the-art BiCuSeO. The results indicate a new scalable method …
The 3 heating modes are utilized to make ZrN powders have 3 different levels of the electric current density at the same temperature during spark plasma sintering (SPS). The constitutive equation of sintering for SPS is applied to the experimental porosity evolution of ZrN from three SPS modes, and this showed high electric current density increase the electric current assisted deformability value of ZrN pellets, resulting in a reduction of the flow stress. The electric current flow enhances the dislocation motion, which was experimentally proved and analyzed by modified Williamson-Hall equati…
Graphite creep has high importance for applications using high pressures (100 MPa) and temperatures close to 2000 {\textdegree}C. In particular, the new flash spark plasma sintering process (FSPS) is highly sensitive to graphite creep when applied to ultra-high temperature materials such as silicon carbide. In this flash process taking only a few seconds, the graphite tooling reaches temperatures higher than 2000 {\textdegree}C resulting in its irreversible deformation. The graphite tooling creep prevents the flash spark plasma sintering process from progressing further. In this study, a finit…
A new flash (ultra-rapid) spark plasma sintering method applicable to various materials systems, regardless of their electrical resistivity, is developed. A number of powders ranging from metals to electrically insulative ceramics have been successfully densified resulting in homogeneous microstructures within sintering times of 8-35 s. A finite element simulation reveals that the developed method, providing an extraordinary fast and homogeneous heating concentrated in the sample's volume and punches, is applicable to all the different samples tested. The utilized uniquely controllable flash p…
This work addresses the two great challenges of the spark plasma sintering (SPS) process: the sintering of complex shapes and the simultaneous production of multiple parts. A new controllable interface method is employed to concurrently consolidate two nickel gear shapes by SPS. A graphite deformable sub-mold is specifically designed for the mutual densification of the both complex parts in a unique 40 mm powder deformation space. An energy efficient SPS configuration is developed to allow the sintering of a large-scale powder assembly under electric current lower than 900 A. The stability of …
A new medium-entropy diboride (MEDB) (W1/3Re1/3Ru1/3)B2 has been synthesized by spark plasma sintering of elemental powders at 1600 oC. Despite the dissimilar structures of WB2, ReB2 and RuB2, the sintered MEDB consists of a single hexagonal ReB2-type phase (space group P63/mmc) with a relative density of 94.2% and an average grain size of 6.8 $\pm$ 2.2 um. Structural refinement and electron microscopy measurements show that the W, Re, and Ru atoms occupy the same crystallographic site and are distributed uniformly in the lattice. The (W1/3Re1/3Ru1/3)B2 MEDB has Vickers hardnesses of 30.7 GPa …
An energy efficient spark plasma sintering method enabling the densification of large size samples assisted by very low electric current levels is developed. In this method, the electric current is concentrated in the graphite foils around the sample. High energy dissipation is then achieved in this area enabling the heating and full densification of large (alumina) parts ({Ø} 40 mm) at relatively low currents (800 A). The electrothermal mechanical simulation reveals that the electric current needed to heat the large samples is 70 % lower in the energy efficient configuration compared to the t…
Spark plasma sintering (SPS) of MgAl2O4 powder was investigated at temperatures between 1200 and 1300°C. A significant grain growth was observed during densification. The densification rate always exhibits at least one strong minimum, and resumes after an incubation period. Transmission electron microscopy investigations performed on sintered samples never revealed extensive dislocation activity in the elemental grains. The densification mechanism involved during SPS was determined by anisothermal (investigation of the heating stage of a SPS run) and isothermal methods (investigation at given …
Spark Plasma Sintering for high-speed diffusion welding of the ultrafine grained near-a Ti-5Al-2V alloy with high strength and corrosion resistance for nuclear engineering
Spark plasma sintering (SPS) technique is applied in combination with hydrogen decrepitation process for the recycling of SmCo5 magnets. The SmCo5 magnets for recycling were first decrepitated by hydrogen gas of a pressure of 4 bar for 3 hours to produce decrepitated powder. This powder was then used to prepare isotropic sintered magnets using the SPS technique, by sintering at 800-1000 oC for 1 minute. Full densification of the SPS-ed magnets was possible at a temperature of 1000 oC. The sample sintered at 900 oC showed the best internal coercivity (jHc) of higher than 1500 kA/m with high rem…
A novel and sustainable method to develop non-equiatomic CoCrFeNiMox high entropy alloys via spark plasma sintering using commercial commodity powders and evaluation of its mechanical behaviour
Although vanadium dioxide (VO2) exhibits the most abrupt metal to insulator transition (MIT) properties near room-temperature, the present regulation of their MIT functionalities is insufficient owing to the high complexity and susception associated with V4+. Herein, we demonstrate a spark plasma assisted reactive sintering (SPARS) approach to simultaneously achieve in situ doping and sintering of VO2 within largely short period (~10 minutes). This enables high convenience and flexibility in regulating the electronic structure of VO2 via dopant elements covering Ti, W, Nb, Mo, Cr and Fe, leadi…
Electric Charge Transport and Dielectric Properties of the Barium Titanate Ceramics Obtained by Spark-Plasma Sintering with Different Carbon Content
Institute of Physics of the National Academy of Sciences of Ukraine（乌克兰国家科学院物理研究所）；Educational Scientific Institute of High Technologies, Taras Shevchenko National University of Kyiv（基辅塔拉斯舍甫琴科国立大学高等技术教育科学研究所）；Frantsevich Institute for Problems in Materials Science, National Academy of Sciences of Ukraine（乌克兰国家科学院弗兰采维奇材料科学问题研究所）；Department of Chemistry, Stockholm University（斯德哥尔摩大学化学系）；Department of Physical Materials Science and Heat Treatment, National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute”（乌克兰国立技术大学“伊戈尔·西科尔斯基基辅理工学院”物理材料科学与热处理系）
In this study, we have compared magnetic and magnetostrictive properties of polycrystalline CoFe$_2$O$_4$ pellets, produced by three different methods, focusing on the use of Spark Plasma Sintering (SPS). This technique allows a very short heat treatment stage while a uniaxial pressure is applied. SPS was utilized to sinter cobalt ferrite but also to make the reaction and the sintering (reactive sintering) of the same ceramic composition. Magnetic and magnetostrictive measurements show that the reactive sintering with SPS induces a uniaxial anisotropy, while it is not the case with a simple si…
A thermodynamically consistent phase-field model is developed to study the non-isothermal grain coalescence during the sintering process, with a potential application to the simulation in unconventional sintering techniques, e.g. spark plasma sintering, field-assisted sintering, and selective laser sintering, where non-equilibrium and high temperature gradient exist. In the model, order parameters are adopted to represent the bulk and atmosphere/pore region, as well as the crystallographic orientations. Based on the entropy analysis, the temperature-dependent free energy density is developed, …
Microwave Pressing is a promising way to reduce microwave sintering temperatures and stabilize microwave powder materials processing. A multi-physics simulation was conducted of the regulated pressure-assisted microwave cavity. This simulation took into consideration resonance phenomena and the nonlinear temperature-dependent material parameters of zirconia. The intrinsic behaviors of microwave systems and zirconia make the regulation of the microwave pressing difficult. However, the same phenomena can be used to activate flash sintering. Flash microwave sintering uses high electric fields of …
We present the synthesis of D0$_{22}$ Mn$_{3 - δ}$Ga ($δ$ = 0, 1) Heusler alloys by Spark Plasma Sintering method. The single phase Mn$_3$Ga (T$_\mathrm{c}$ $\simeq$ 780 K) is synthesized, while Mn$_2$Ga (T$_\mathrm{c}$ $\simeq$ 710 K) is found to coexist with a near-stoichiometric room temperature paramagnetic Mn$_9$Ga$_5$~($\approx$ 15 \%) phase due to its lower formation energy, as confirmed from our density functional theory (DFT) calculations. The alloys show hard magnetic behavior with large room temperature spontaneous magnetization m$_s$(80 kOe) = 1.63 (0.83) $μ_\mathrm{B}$/f.u. and co…
Impact of Carbon Contamination on the Low-Temperature Electric Conduction of the Spark-Plasma Sintered Barium Titanate Ceramics
Institute of Physics of the National Academy of Sciences of Ukraine（乌克兰国家科学院物理研究所）；Frantsevich Institute for Problems in Materials Science, National Academy of Sciences of Ukraine（乌克兰国家科学院弗兰特谢维奇材料科学问题研究所）；V. Lashkarev Institute of Semiconductor Physics, National Academy of Sciences of Ukraine（乌克兰国家科学院瓦·拉舍列夫半导体物理研究所）
The effect of temperature modes and heating rates (Vh) on the shrinkage kinetics of submicron and fine aluminum oxide powders has been studied. The objects of research comprised (i) submicron alfa-Al2O3 powder, (ii) submicron alfa-Al2O3 powder with an amorphous layer on particle surface, (iii) fine alfa-Al2O3 powder. The alumina ceramic specimens were produced by Spark Plasma Sintering (SPS). Equally fine powders (i) and (ii) were used to analyze the effect of an amorphous layer on sintering kinetics. Powders (i) and (iii) were used to analyze the effect of the initial particle size on shrinka…
Combined Thermal Expansion and Hydrolytic Stability Study of Lanthanide Vanadates LnVO4 and CaLnZr(VO4)3 (Ln = La, Nd, Sm, Eu, Gd, Dy, Yb) with Zircon and Monazite Structures
