Simultaneous Spark Plasma Sintering of Multiple Complex Shapes
Abstract
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.
- Authors:
-
- San Diego State Univ., CA (United States)
- San Diego State Univ., CA (United States); Univ. of San Diego, San Diego, CA (United States)
- Publication Date:
- Research Org.:
- San Diego State Univ., CA (United States)
- Sponsoring Org.:
- USDOE Office of Science (SC)
- OSTI Identifier:
- 1611092
- Grant/Contract Number:
- SC0008581
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Materials
- Additional Journal Information:
- Journal Volume: 12; Journal Issue: 4; Journal ID: ISSN 1996-1944
- Publisher:
- MDPI
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; Materials Science; spark plasma sintering; complex shapes; energy efficient; multiple parts; multiphysics simulation; deformed interface method
Citation Formats
Manière, Charles, Torresani, Elisa, and Olevsky, Eugene. Simultaneous Spark Plasma Sintering of Multiple Complex Shapes. United States: N. p., 2019.
Web. doi:10.3390/ma12040557.
Manière, Charles, Torresani, Elisa, & Olevsky, Eugene. Simultaneous Spark Plasma Sintering of Multiple Complex Shapes. United States. https://doi.org/10.3390/ma12040557
Manière, Charles, Torresani, Elisa, and Olevsky, Eugene. Wed .
"Simultaneous Spark Plasma Sintering of Multiple Complex Shapes". United States. https://doi.org/10.3390/ma12040557. https://www.osti.gov/servlets/purl/1611092.
@article{osti_1611092,
title = {Simultaneous Spark Plasma Sintering of Multiple Complex Shapes},
author = {Manière, Charles and Torresani, Elisa and Olevsky, Eugene},
abstractNote = {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.},
doi = {10.3390/ma12040557},
journal = {Materials},
number = 4,
volume = 12,
place = {United States},
year = {Wed Feb 13 00:00:00 EST 2019},
month = {Wed Feb 13 00:00:00 EST 2019}
}
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Local Distortions in Nanostructured Ferroelectric Ceramics through Strain Tuning
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Steady-state creep of pure polycrystalline nickel from 0.3 to 0.55 Tm
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- Acta Metallurgica, Vol. 18, Issue 6
Spark-plasma-sintering and finite element method: From the identification of the sintering parameters of a submicronic α-alumina powder to the development of complex shapes
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Effect of electric current on densification behavior of conductive ceramic powders consolidated by spark plasma sintering
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Finite element analysis of the temperature uncertainty during spark plasma sintering: Influence of the experimental procedure
journal, December 2017
- Achenani, Youssef; Saâdaoui, Malika; Cheddadi, Abdelkhalek
- Ceramics International, Vol. 43, Issue 17
Pulse analysis and electric contact measurements in spark plasma sintering
journal, October 2015
- Maniere, C.; Pavia, A.; Durand, L.
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In-situ creep law determination for modeling Spark Plasma Sintering of TiAl 48-2-2 powder
journal, July 2017
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Densification and properties of bulk nanocrystalline functional ceramics with grain size below 50nm
journal, June 2013
- Maglia, Filippo; Tredici, Ilenia G.; Anselmi-Tamburini, Umberto
- Journal of the European Ceramic Society, Vol. 33, Issue 6
Contact resistances in spark plasma sintering: From in-situ and ex-situ determinations to an extended model for the scale up of the process
journal, April 2017
- Manière, Charles; Durand, Lise; Brisson, Elodie
- Journal of the European Ceramic Society, Vol. 37, Issue 4
Electro-thermal measurements and finite element method simulations of a spark plasma sintering device
journal, August 2013
- Pavia, A.; Durand, L.; Ajustron, F.
- Journal of Materials Processing Technology, Vol. 213, Issue 8
Finite element modeling of spark plasma sintering: Application to the reduction of temperature inhomogeneities, case of alumina
journal, February 2017
- Achenani, Youssef; Saâdaoui, Malika; Cheddadi, Abdelkhalek
- Materials & Design, Vol. 116
Thermal-electrical-mechanical simulation of the nickel densification by Spark Plasma Sintering. Comparison with experiments
journal, September 2016
- Wolff, Cyprien; Mercier, Sébastien; Couque, Hervé
- Mechanics of Materials, Vol. 100
Consolidation/synthesis of materials by electric current activated/assisted sintering
journal, February 2009
- Orrù, Roberto; Licheri, Roberta; Locci, Antonio Mario
- Materials Science and Engineering: R: Reports, Vol. 63, Issue 4-6, p. 127-287
Spark plasma sintering and complex shapes: The deformed interfaces approach
journal, October 2017
- Manière, Charles; Nigito, Emmanuel; Durand, Lise
- Powder Technology, Vol. 320
Preface and historical perspective on spark plasma sintering
journal, July 2013
- Risbud, Subhash H.; Han, Young-Hwan
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A sacrificial material approach for spark plasma sintering of complex shapes
journal, November 2016
- Manière, Charles; Durand, Lise; Weibel, Alicia
- Scripta Materialia, Vol. 124
Porosity dependence of powder compaction constitutive parameters: Determination based on spark plasma sintering tests
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- Manière, Charles; Olevsky, Eugene A.
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Near net shape processing of a sintered alumina component: adjustment of pressing parameters through finite element simulation
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Ultra-fast and energy-efficient sintering of ceramics by electric current concentration
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- Scientific Reports, Vol. 5, Issue 1
Flash (Ultra-Rapid) Spark-Plasma Sintering of Silicon Carbide
journal, September 2016
- Olevsky, Eugene A.; Rolfing, Stephen M.; Maximenko, Andrey L.
- Scientific Reports, Vol. 6, Issue 1
Effects of Particle Packing Characteristics on Solid-State Sintering
journal, May 1989
- Zheng, Jingmin; Reed, James S.
- Journal of the American Ceramic Society, Vol. 72, Issue 5
Fundamental Aspects of Spark Plasma Sintering: II. Finite Element Analysis of Scalability
journal, May 2012
- Olevsky, Eugene A.; Garcia-Cardona, Cristina; Bradbury, William L.
- Journal of the American Ceramic Society, Vol. 95, Issue 8
Flash Spark Plasma Sintering (FSPS) of Pure ZrB 2
journal, July 2014
- Grasso, Salvatore; Saunders, Theo; Porwal, Harshit
- Journal of the American Ceramic Society, Vol. 97, Issue 8
Effects of Current Confinement on the Spark Plasma Sintering of Silicon Carbide Ceramics
journal, June 2015
- Román-Manso, Benito; Belmonte, Manuel; Osendi, María Isabel
- Journal of the American Ceramic Society, Vol. 98, Issue 9
Current understanding and future research directions at the onset of the next century of sintering science and technology
journal, May 2017
- Bordia, Rajendra K.; Kang, Suk-Joong L.; Olevsky, Eugene A.
- Journal of the American Ceramic Society, Vol. 100, Issue 6
Energy efficient spark plasma sintering: Breaking the threshold of large dimension tooling energy consumption
journal, September 2018
- Manière, Charles; Lee, Geuntak; McKittrick, Joanna
- Journal of the American Ceramic Society
Temperature Control in Spark Plasma Sintering: An FEM Approach
journal, January 2010
- Molénat, G.; Durand, L.; Galy, J.
- Journal of Metallurgy, Vol. 2010
Spark Plasma Sintering of Commercial Zirconium Carbide Powders: Densification Behavior and Mechanical Properties
journal, September 2015
- Wei, Xialu; Back, Christina; Izhvanov, Oleg
- Materials, Vol. 8, Issue 9
All-Materials-Inclusive Flash Spark Plasma Sintering
text, January 2020
- Manière, Charles; Lee, Geuntak; Olevsky, Eugene A.
- arXiv