Simultaneous Spark Plasma Sintering of Multiple Complex Shapes

• DOI: 10.3390/ma12040557
• Publication Date: 2019-02-14T08:21:46Z
• Authors: Charles Manière; Elisa Torresani; Eugene A. Olevsky
• Keywords: 670; FOS: Physical sciences; Multiple Parts; 02 engineering and technology; 530; 01 natural sciences; 7. Clean energy; Article; Multiphysics Simulation; multiphysics simulation; deformed interface method; Complex Shapes; Deformed Interface Method; multiple parts; [SPI.MECA.MEMA]Engineering Sciences [physics]/Mechanics [physics.med-ph]/Mechanics of materials [physics.class-ph]; 0103 physical sciences; [SPI.GPROC]Engineering Sciences [physics]/Chemical and Process Engineering; energy efficient; Spark Plasma Sintering; Condensed Matter - Materials Science; complex shapes; Materials Science (cond-mat.mtrl-sci); [CHIM.MATE]Chemical Sciences/Material chemistry; Energy Efficient; 0205 materials engineering; spark plasma sintering

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 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 the developed process is studied by electro-thermal-mechanical (ETM) simulation. The ETM simulation reveals that homogeneous densification conditions can be attained by inserting an alumina powder at the sample/punches interfaces, enabling the energy efficient heating and the thermal confinement of the nickel powder. Finally, the feasibility of the fabrication of the two near net shape gears with a very homogeneous microstructure is demonstrated.