Fully coupled electrothermal and mechanical simulation of the production of complex shapes by spark plasma sintering

Laan, A. Van der; Epherre, Romain; Chevallier, Geoffroy; Beynet, Yannick; Weibel, Alicia; Estournès, Claude

doi:10.1016/j.jeurceramsoc.2021.02.010

Cited by 7 publications

(3 citation statements)

References 28 publications

(49 reference statements)

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“…[91] This requires the experimental identification of creep parameters. [11,[92][93][94] The more sophisticated models consider grain growth, which affects the densification mechanisms-especially at the end stage of sintering. [87,88,95] Several papers describe the basics of FAST/SPS modeling in detail.…”

Section: Basicsmentioning

confidence: 99%

Tooling in Spark Plasma Sintering Technology: Design, Optimization, and Application

Laptev,

Bram,

Garbiec

et al. 2024

Adv Eng Mater

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Spark plasma sintering as the prominent field‐assisted sintering technique (FAST/SPS) is a novel technology for the rapid, pressure‐assisted consolidation of powder materials. The main feature of FAST/SPS is the Joule heating of the used tooling. Tooling is a core part of the FAST/SPS setup, which must withstand high pressure at elevated temperatures ensuring a uniform temperature distribution inside the sintered part. This review looks at the standard FAST/SPS tooling, the specific tooling used for sintering complex‐shaped parts and for pressureless sintering. A particular focus lies on the graphite, the commonly used tooling material, and on alternative materials such as steel, alloys, ceramics, and composites. The review also considers the add‐on tooling elements, including spacers, foils, and thermal insulation. Furthermore, the paper discusses the basics of FAST/SPS modeling, the computer‐based optimization of FAST/SPS tooling, the simulation procedure used, and the modelling accuracy. The review briefly describes the tooling and equipment for manufacturing upsized parts and large‐scale production. In addition, the paper considers the tooling for FAST/SPS sintering under high pressure (up to 1 GPa) and ultra‐high pressure (over 1 GPa). The paper concludes with an analysis of the challenges and prospective solutions for the continued development of FAST/SPS tooling.This article is protected by copyright. All rights reserved.

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Section: Basicsmentioning

confidence: 99%

Tooling in Spark Plasma Sintering Technology: Design, Optimization, and Application

Laptev,

Bram,

Garbiec

et al. 2024

Adv Eng Mater

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“…[22] In contrast, it is advantageous to use granules for making complex-shaped components by SPS. [23] Granules have been sometimes used for SPS of alumina, [24,25] zirconia, [26,27] monolithic SiC ceramic, [28,29] magnesium aluminate spinel, [30] carbon nanotube (CNT)-incorporated aluminazirconia composite, [31] quasi-crystalline materials, [32] and microporous alumina. [33] We aim to present a model experiment for understanding the shrinkage of defects in SPS of granules.…”

Section: Introductionmentioning

confidence: 99%

3D Visualization of Morphological Evolution of Large Defects during Spark Plasma Sintering of Alumina Granules

et al. 2023

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The mechanical reliability of products must be assured for scaling up and production of complex‐shaped components by spark plasma sintering (SPS) of spray‐dried granules. The evolution of morphologies of pores and defects, which control the mechanical strength, is investigated by using synchrotron X‐ray multiscale tomography during SPS of alumina granules at 1300 °C. While large defects arising from the hierarchical granule packing structure cannot be removed by pressureless sintering, crack‐like defects and branched rodlike defects are almost eliminated by SPS at stresses higher than 30 and 50 MPa, respectively. But, small ellipsoidal porous regions, which may arise from aggregates or dimples of granules, cannot be removed even at a pressure of 50 MPa. A very large defect is also found by using micro‐CT. It is supposed that this defect is formed from a large void in loosely packed granules. The shrinkage of large voids and the elimination of crack‐like defects are explained by the theoretical prediction based on the continuum theory of sintering.

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“…To accomplish this, parameters need to be optimized, and using trial and error is often costly and time-consuming. With this in mind, some researchers [17][18][19] believe numerical simulation of FAST in parallel with experimental tests is necessary for optimization. The summary of the literature reveals that for predicting the density evolution in the sintering process, there is no existing systematic material parameter identification framework that can demonstrate valid results using various processing conditions.…”

Section: Introductionmentioning

confidence: 99%

Nickel Coatings on Ceramic Materials Using Different Diffusion Techniques

Sharma,

Stutzman,

Schreiber

et al. 2023

Coatings

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Diffusion bonding is a process that has proven effective for the joining of metal to ceramic, but the differences in coefficient of thermal expansion still pose challenges during and after the bonding process. This work details the exploration of traditional diffusion-bonding processes using two traditional approaches, which include bonding of a 99.9+% pure Ni foil to SiC, Si3N4, and YSZ disks using (1) a hot isostatic press (HIP), with and without added weight to promote interfacial contact, and (2) field-assisted sintering (FAST). Samples were consolidated by heating to 1200 °C and held for 6 h under vacuum before cooling to room temperature during the HIP method. For the FAST technique, bonding experiments were performed at both 800 °C and 1200 °C in a vacuum environment under 10 MPa uniaxial pressure. After the Ni was bonded to the ceramics, diffusion heat treatments were carried out in the HIP. For electroless-plated samples, the heat-treatment temperature was chosen as 825 °C to avoid melting. For electroplated samples, heat treatment occurred at 925 °C or higher. Electroplated YSZ samples were heat-treated at 1150 °C as the Ni-Si eutectic is not a concern in this system. The time at temperature varied from 6 h to 48 h depending on the material combination tested. Post-heat-treatment diffusion characteristics were analyzed using scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS). A main cause of poor bonding performance in the HIP samples was reduced interfacial contact, while cohesive failures in the FAST samples are likely due to the formation of brittle intermetallic Ni-Si phases. Preliminary results indicate success in bonding Ni to SiC, Si3N4, and YSZ using a diffusion-enhanced approach on electroplated specimens.

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Fully coupled electrothermal and mechanical simulation of the production of complex shapes by spark plasma sintering

Cited by 7 publications

References 28 publications

Tooling in Spark Plasma Sintering Technology: Design, Optimization, and Application

Tooling in Spark Plasma Sintering Technology: Design, Optimization, and Application

3D Visualization of Morphological Evolution of Large Defects during Spark Plasma Sintering of Alumina Granules

Nickel Coatings on Ceramic Materials Using Different Diffusion Techniques

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