Papers by Keyword: Spark Plasma Sintering (SPS)

Abstract: The microstructure and optical properties are investigated for MgO-doped alumina fabricated by spark plasma sintering at temperatures between 1100 and 1550 °C. The MgO doping renders the microstructure less sensitive to the sintering temperature by suppressing grain growth, whereas it has no significant effect on the densification of alumina and resultantly no effect in enhancing the total forward transmission. The value of the total forward transmission can be used as an indirect measure of the slight change in density.

Abstract: The densification mechanism in park-plasma-sintering (SPS) processing was examined in MgAl2O4 spinel. As the relative density ρt increases, that is, as the effective stress σeff decreases, stress exponent n evaluated from effective stress-densification rate relationship continuously varies from n  4 to n  1. TEM observation shows that significant stacking faults caused by partial dislocations are frequently observed in the low ρt region. The results suggest that, for spinel, the predominant densification mechanism in SPS processing changes with ρt from plastic flow by a partial dislocation motion in the low ρt region (n  4) to diffusion-related creep in the high ρt region (n  1).

Abstract: Aeronautic gas turbine blades, vanes and combustion chambers are protected against high temperature oxidation and corrosion by single or multilayered coatings. These include environmental coatings, generally based on Pt-modified Ni aluminides or MCrAlY overlays (where M = Ni and/or Co), thermal barrier coating (TBC) systems including a ceramic thermally insulating layer, and abradable seals. The present work shows the ability of the Spark Plasma Sintering technique to rapidly develop new coatings compositions and microstructures. This technique allows combining powders and metallic foils on a superalloy substrate in order to obtain multilayered coatings in a single short production step. Fabrication of MCrAlY overlays with local Pt and/or Al enrichments is shown, as well as fabrication of coatings made of -PtAl2, -PtAl, α-AlNiPt2, martensitic and (Ni,Pt)Al or Pt-rich ’ phases, including their doping with reactive elements. The fabrication of a complete TBC system with a porous and adherent Yttria Stabilized Zirconia (YSZ) layer on a bond-coating is also demonstrated, as well as the fabrication of a CoNiCrAlY-based cermet coating for abradable seal application. Difficulties of fabrication are reviewed, such as Y segregation, risks of carburization, local over-heating, or difficulty to coat complex shaped parts. Solutions are given to overcome these difficulties.

Abstract: We investigated consolidation behavior of gas-atomized Cu50Zr45Al5 metallic glassy alloy powders by a spark plasma sintering (SPS) process. Density of the sintered samples increased with an increase in sintering temperature. The nearly full density samples without crystallization could be attained by the SPS process at sintering temperature of 693 K under pressure of 600 MPa. The produced samples exhibited high-strength and met large-size requirement. The SPS process makes it possible to fabricate the large-size bulk metallic glasses without limitation of dimensions and alloy system.

Abstract: In this study, we focused on the sintering performance of Ti-4.5Al-3V-2Mo-2Fe (SP-700) and mechanical properties of SP-700 reinforced with titanium boride (TiB/SP-700) fabricated by spark plasma sintering (SPS). TiB whiskers formed in titanium by a solid-state reaction of titanium and TiB2 particles were analyzed with scanning electron microscopy and X-ray diffraction. The TiB/SP-700 was sintered at temperatures of 1073, 1173, and 1273 K and a pressure of 70 MPa for 10, 30, and 50 min. The volume fraction of TiB ranged from 1.7 vol.% to 19.9 vol.%. Tensile tests of TiB/SP-700 were conducted at room temperature, and the effect of TiB volume fraction on the tensile properties was investigated.

Abstract: Spark-plasma sintering (SPS) is an emerging powder consolidating technique which provides significant advantages to the processing of high temperature materials with poor deformability into configurations previously unattainable. Net-shaping capabilities of spark-plasma sintering are analyzed both theoretically and experimentally. Modeling and experimentation are conducted for cylindrical, prismatic, and complex powder specimen shapes. The impact of the “shape factor” on the non-uniformity of temperature, relative density, and grain size spatial distributions is analyzed. The modeling results are compared to the experimentally obtained data on the spark plasma sintering of high strength temperature resistant powder-based materials. The conducted research indicates the promising capabilities and addresses the challenges of spark-plasma sintering of complex-shape parts.

Abstract: In this paper, rare-earth fluorides were used as sintering additives instead of rare-earth oxides, the influence of the type and the amount of the fluoride on the thermal conductivity, hardness and strength of Si3N4 ceramics was studied. Results show that the thermal conductivity of a sample sintered with CeF3 is nearly 10% higher than that of the sample sintered with Ce2O3, while the samples sintered with LaF3 increases further 15% as comparing with the samples sintered with CeF3. The strength of the samples changes reversely. These results express that the thermal conductivity of Si3N4 ceramics can be improved by using rare-earth fluoride additives instead of the oxides, and the type of rare-earth fluorides has a significant impact on the properties of Si3N4 ceramics.

Abstract: A finite element model (FEM) is developed to simulate the temperature distribution in the sample/die/punch assembly during the spark plasma sintering (SPS) process. A thermal–electrical coupled model with temperature dependent thermal and electrical properties is implemented. The simulation studies were conducted using COMSOL and a range of heating-rates and die sizes were considered. Also, both temporary and equilibrium condition during heating process were evaluated in order to express the real temperature development in the sintering. During the spark plasma sintering process, the temperature difference between the sample center and the die surface depend on the heating-rate and die size. The simulation results also revealed that the temperature gradient during the heating process is much bigger than that in the dwelling period. It is necessary to consider the temporary state during the spark plasma sintering process in order to guarantee a well–controlled microstructure, especially in non-conductive ceramic materials.

Abstract: The precursor of Ca2Co2O5 was prepared by coprecipitation method. The bulk Ca2Co2O5 samples were prepared by conventional sintering and Spark Plasma Sintering (SPS), respectively. The relative density of bulk Ca2Co2O5 ceramic, which was prepared by conventional sintering is about 75%; while the samples prepared by SPS has a density of 98%. The thermoelectric properties were enhanced by SPS, compared with samples prepared with conventional sintering. The maximum powerfactor of the conventional sintering and SPS samples are 2.70×10-4W∙m-1∙K-2 and 3.85×10-4 W∙m-1∙K-2, respectively.

Abstract: A series of polycrystalline (Ca1-xBix)3Co4O9 ( x = 0.0 ~ 0.075 ) powders were synthesized rapidly by a polyacrylamide gel method. The dense ceramics were fabricated using the spark plasma sintering ( SPS ) technique. Effects of Bi substitution on high temperature thermoelectric properties of Ca3Co4O9 were evaluated. Both the electrical conductivity and Seebeck coefficient increased with increasing Bi content up to x = 0.05, thus leading to an enhanced thermoelectric power factor. The Bi substituted sample with x = 0.05 obtained in this study has the highest thermoelectric power factor in the measured temperature range. It reaches 4.810-4 Wm-1K-2 at 700 °C, which is 26 % higher than that of Ca3Co4O9 without Bi substitution, and is by up to 15 % larger as compared to the Bi substituted sample synthesized by the solid state reaction method and the SPS technique due to the high chemical homogeneous powder prepared by the polyacrylamide gel method.