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In this study, the evolution of the electrical resistivity of metal powders during densification and the resulting current flow through punch, powder compact, and die is investigated. The evaluation of the accompanying Joule heating identifies the graphite punches as main heating element providing more than 90% of the heat. The high electrical resistance of the punches and the low resistance of the graphite die as parallel electrical load to the specimen determine the current flow in the tool. For powder particles with intact oxide layers, virtually no current flows through the compact. On the other hand, for a powder resistivity below 10 −3 Ωcm about 50% of the current flows through the compact. This fraction is constant despite further decreasing resistivity of the compact during densification. A constant current through the specimen has important implications for the microscopic temperature distribution and the understanding of the so-called 'spark plasma effects'.

The temperature distribution in copper and martensitic steel spheres has been investigated for the initial stage of field-activated sintering (FAST)/spark plasma sintering (SPS) using capacitor discharges (CD) with applied voltages from one to 15 V as model experiments. At first, the evolution of the contact resistance between the spheres has been studied. The results show the reduction in the contact resistance after discharge with increasing electrical load, yet no significant dependence on the length or number of the discharge pulses. Thereby the initial resistance is only decreased distinctly if at least a certain minimal voltage was applied. Subsequently, the melting of thin coatings of different metals on copper spheres has been studied and the occurrence of molten phase and its melting point were assigned to the corresponding discharge current. Extrapolation from the currents necessary to melt the coating layers in the CD experiments to lower values typical for FAST was used to estimate the contact overtemperature in the latter case. Resulting values for copper range from 0.05 K for normal heating with 100 K/min to 5 K for maximum current output.

The mechanisms of densification in spark plasma sintering (SPS) were investigated both analytically and numerically for a model system of two spherical metallic powder particles. From the microscopic temperature distribution, the possibility of a micro-local overheating of the particleparticle contacts was analysed for different particle sizes, contact geometries, materials, and electrical loads. It is shown that, for particles below the size of one millimetre, local overheating is below one Kelvin. Subsequently, the material transport by thermomigration, electromigration, and diffusion driven by surface curvature and external pressure was derived from microscopic field distributions obtained from analytical calculations and finite-element simulations. The results show that, while the mechanical pressure accelerates material transport by orders of magnitude, the electrical current and the temperature gradients do not. It is also shown that pulsing the current has no significant influence on the densification rate.

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