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Title: All-Materials-Inclusive Flash Spark Plasma Sintering

Abstract

A new flash (ultra-rapid) spark plasma sintering method applicable to various materials systems, regardless of their electrical resistivity, is developed. A number of powders ranging from metals to electrically insulative ceramics have been successfully densified resulting in homogeneous microstructures within sintering times of 8–35 s. A finite element simulation reveals that the developed method, providing an extraordinary fast and homogeneous heating concentrated in the sample’s volume and punches, is applicable to all the different samples tested. The utilized uniquely controllable flash phenomenon is enabled by the combination of the electric current concentration around the sample and the confinement of the heat generated in this area by the lateral thermal contact resistance. The presented new method allows: extending flash sintering to nearly all materials, controlling sample shape by an added graphite die, and an energy efficient mass production of small and intermediate size objects. This approach represents also a potential venue for future investigations of flash sintering of complex shapes.

Authors:
 [1];  [1];  [1]
  1. San Diego State Univ., San Diego, CA (United States)
Publication Date:
Research Org.:
San Diego State Univ., CA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1500042
Grant/Contract Number:  
SC0008581
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
Scientific Reports
Additional Journal Information:
Journal Volume: 7; Journal Issue: 1; Journal ID: ISSN 2045-2322
Publisher:
Nature Publishing Group
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE

Citation Formats

Manière, Charles, Lee, Geuntak, and Olevsky, Eugene A. All-Materials-Inclusive Flash Spark Plasma Sintering. United States: N. p., 2017. Web. doi:10.1038/s41598-017-15365-x.
Manière, Charles, Lee, Geuntak, & Olevsky, Eugene A. All-Materials-Inclusive Flash Spark Plasma Sintering. United States. https://doi.org/10.1038/s41598-017-15365-x
Manière, Charles, Lee, Geuntak, and Olevsky, Eugene A. 2017. "All-Materials-Inclusive Flash Spark Plasma Sintering". United States. https://doi.org/10.1038/s41598-017-15365-x. https://www.osti.gov/servlets/purl/1500042.
@article{osti_1500042,
title = {All-Materials-Inclusive Flash Spark Plasma Sintering},
author = {Manière, Charles and Lee, Geuntak and Olevsky, Eugene A.},
abstractNote = {A new flash (ultra-rapid) spark plasma sintering method applicable to various materials systems, regardless of their electrical resistivity, is developed. A number of powders ranging from metals to electrically insulative ceramics have been successfully densified resulting in homogeneous microstructures within sintering times of 8–35 s. A finite element simulation reveals that the developed method, providing an extraordinary fast and homogeneous heating concentrated in the sample’s volume and punches, is applicable to all the different samples tested. The utilized uniquely controllable flash phenomenon is enabled by the combination of the electric current concentration around the sample and the confinement of the heat generated in this area by the lateral thermal contact resistance. The presented new method allows: extending flash sintering to nearly all materials, controlling sample shape by an added graphite die, and an energy efficient mass production of small and intermediate size objects. This approach represents also a potential venue for future investigations of flash sintering of complex shapes.},
doi = {10.1038/s41598-017-15365-x},
url = {https://www.osti.gov/biblio/1500042}, journal = {Scientific Reports},
issn = {2045-2322},
number = 1,
volume = 7,
place = {United States},
year = {Wed Nov 08 00:00:00 EST 2017},
month = {Wed Nov 08 00:00:00 EST 2017}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record

Citation Metrics:
Cited by: 70 works
Citation information provided by
Web of Science

Figures / Tables:

Figure 1 Figure 1: Experimental electric current (a,c) and displacement (b,d) curves under constant current mode (a,b) and forced mode (c,d).

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Works referenced in this record:

Flash Spark Plasma Sintering (FSPS) of α and β SiC
journal, February 2016


Electric field-induced softening of alkali silicate glasses
journal, November 2015


Modeling of SPS apparatus: Temperature, current and strain distribution with no powders
journal, January 2007


Evidence for a non-thermal microwave effect in the sintering of partially stabilized zirconia
journal, April 1996


Flash sintering of alumina: Effect of different operating conditions on densification
journal, August 2016


Proportional integral derivative, modeling and ways of stabilization for the spark plasma sintering process
journal, January 2017


Experimental Investigation of Electric Contact Resistance in Spark Plasma Sintering Tooling Setup
journal, May 2015


Modelling of the temperature distribution during field assisted sintering
journal, September 2005


Flash Spark Plasma Sintering (FSPS) of Pure ZrB 2
journal, July 2014


Temperature evolution during field activated sintering
journal, August 2004


Intrinsic Electrical Conductivity in Silicon Carbide
journal, September 1957


Microwave Sintering of Alumina at 2.45 GHz
journal, August 2003


Flash spark plasma sintering of ultrafine yttria-stabilized zirconia ceramics
journal, August 2016


Estimating Joule heating and ionic conductivity during flash sintering of 8YSZ
journal, February 2016


Preface and historical perspective on spark plasma sintering
journal, July 2013


Microwave Sintering: Fundamentals and Modeling
journal, March 2013


Consolidation/synthesis of materials by electric current activated/assisted sintering
journal, February 2009


Finite-element modeling of the electro-thermal contacts in the spark plasma sintering process
journal, February 2016


Pulse analysis and electric contact measurements in spark plasma sintering
journal, October 2015


Inherent heating instability of direct microwave sintering process: Sample analysis for porous 3Y-ZrO2
journal, February 2017


Ultra-fast and energy-efficient sintering of ceramics by electric current concentration
journal, February 2015


On the Mechanism of Microwave Flash Sintering of Ceramics
journal, August 2016


Photoemission during flash sintering: An interpretation based on thermal radiation
journal, August 2017


Microwave Sintering: Fundamentals and Modeling
journal, March 2013


Ultra-fast firing: Effect of heating rate on sintering of 3YSZ, with and without an electric field
journal, June 2017


Modeling of the temperature distribution of flash sintered zirconia
journal, January 2011


Flash (Ultra-Rapid) Spark-Plasma Sintering of Silicon Carbide
journal, September 2016


Effects of Current Confinement on the Spark Plasma Sintering of Silicon Carbide Ceramics
journal, June 2015


Theoretical and phenomenological analogies between flash sintering and dielectric breakdown in α-alumina
journal, October 2016


Electric current activated/assisted sintering ( ECAS ): a review of patents 1906–2008
journal, October 2009


From conventional ac flash-sintering of YSZ to hyper-flash and double flash
journal, October 2013


Flash sintering as a nucleation phenomenon and a model thereof
journal, December 2014


Flash-sintering of Co2MnO4 spinel for solid oxide fuel cell applications
journal, February 2011


Flash spark plasma sintering of cold-Pressed TiB 2 - h BN
journal, July 2017


Electrical characteristics of flash sintering: thermal runaway of Joule heating
journal, June 2015


Preliminary investigation of flash sintering of SiC
journal, November 2013


Field assisted and flash sintering of alumina and its relationship to conductivity and MgO-doping
journal, December 2011


Hot Pressing of Ceramic Powders
journal, September 1960


Flash spark plasma sintering of ultrafine yttria-stabilized zirconia ceramics
journal, August 2016


Flash Sintering of Anode-Electrolyte Multilayers for SOFC Applications
journal, April 2013


Electric field-induced softening of alkali silicate glasses
journal, November 2015


Electrode Effects on Microstructure Formation During FLASH Sintering of Yttrium-Stabilized Zirconia
journal, April 2016


Electrode Effects on Microstructure Formation During FLASH Sintering of Yttrium-Stabilized Zirconia
journal, April 2016


Temperature evolution during field activated sintering
journal, August 2004


Flash Sintering of Anode-Electrolyte Multilayers for SOFC Applications
journal, April 2013


Preface and historical perspective on spark plasma sintering
journal, July 2013


Electrical Properties of Mn 3− x Co x O 4 (0 ≤  x  ≤ 3) Ceramics: An Interesting System for Negative Temperature Coefficient Thermistors
journal, March 2012


Electrical characteristics of flash sintering: thermal runaway of Joule heating
journal, June 2015


Field assisted and flash sintering of alumina and its relationship to conductivity and MgO-doping
journal, December 2011


Proportional integral derivative, modeling and ways of stabilization for the spark plasma sintering process
journal, January 2017


The effect of electric field and pressure on the synthesis and consolidation of materials: A review of the spark plasma sintering method
journal, February 2006


Flash spark plasma sintering of cold-Pressed TiB 2 - h BN
journal, July 2017


Modeling of SPS apparatus: Temperature, current and strain distribution with no powders
journal, January 2007


Flash Sintering of Nanograin Zirconia in <5 s at 850°C
journal, September 2010


Consolidation enhancement in spark-plasma sintering: Impact of high heating rates
journal, December 2007


Densification and microstructure evolution of Y-Tetragonal Zirconia Polycrystal powder during direct and hybrid microwave sintering in a single-mode cavity
journal, April 2010


Microwave Sintering of Alumina at 2.45 GHz
journal, August 2003


Flash sintering as a nucleation phenomenon and a model thereof
journal, December 2014


Temperature gradient and microstructure evolution in AC flash sintering of 3 mol% yttria-stabilized zirconia
journal, September 2016


Preliminary investigation of flash sintering of SiC
journal, November 2013


Flash sintering of alumina: Effect of different operating conditions on densification
journal, August 2016


Ultra-fast and energy-efficient sintering of ceramics by electric current concentration
journal, February 2015


Dog-bone copper specimens prepared by one-step spark plasma sintering
journal, July 2015


Thermal Runaway in Mold‐Assisted Flash Sintering
journal, July 2016


Flash (Ultra-Rapid) Spark-Plasma Sintering of Silicon Carbide
journal, September 2016


Review of flash sintering: materials, mechanisms and modelling
journal, December 2016


Densification and enhancement of the grain boundary conductivity of gadolinium-doped barium cerate by ultra fast flash grain welding
journal, August 2012


Inherent heating instability of direct microwave sintering process: Sample analysis for porous 3Y-ZrO2
journal, February 2017


Thermal Runaway in Mold‐Assisted Flash Sintering
journal, July 2016


An overview on microwave processing of material: A special emphasis on glass melting
journal, January 2016


Dog-bone copper specimens prepared by one-step spark plasma sintering
journal, July 2015


Hot Pressing of Ceramic Powders
journal, September 1960


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


Consolidation enhancement in spark-plasma sintering: Impact of high heating rates
journal, December 2007


From conventional ac flash-sintering of YSZ to hyper-flash and double flash
journal, October 2013


Flash Sintering of Nanograin Zirconia in <5 s at 850°C
journal, September 2010


Review of flash sintering: materials, mechanisms and modelling
journal, December 2016


Fully coupled electromagnetic-thermal-mechanical comparative simulation of direct vs hybrid microwave sintering of 3Y-ZrO 2
journal, March 2017


Modelling of the temperature distribution during field assisted sintering
journal, September 2005


Flash-sintering of Co2MnO4 spinel for solid oxide fuel cell applications
journal, February 2011


Finite-element modeling of the electro-thermal contacts in the spark plasma sintering process
journal, February 2016


The effect of electric field and pressure on the synthesis and consolidation of materials: A review of the spark plasma sintering method
journal, February 2006


Estimating Joule heating and ionic conductivity during flash sintering of 8YSZ
journal, February 2016


On the Mechanism of Microwave Flash Sintering of Ceramics
journal, August 2016


Theoretical and phenomenological analogies between flash sintering and dielectric breakdown in α-alumina
journal, October 2016


Flash Spark Plasma Sintering (FSPS) of Pure ZrB 2
journal, July 2014


Densification and microstructure evolution of Y-Tetragonal Zirconia Polycrystal powder during direct and hybrid microwave sintering in a single-mode cavity
journal, April 2010


Experimental Investigation of Electric Contact Resistance in Spark Plasma Sintering Tooling Setup
journal, May 2015


Effects of Current Confinement on the Spark Plasma Sintering of Silicon Carbide Ceramics
journal, June 2015


Ultra-fast firing: Effect of heating rate on sintering of 3YSZ, with and without an electric field
journal, June 2017


Ultrafast-Contactless Flash Sintering using Plasma Electrodes
journal, June 2016


Temperature gradient and microstructure evolution in AC flash sintering of 3 mol% yttria-stabilized zirconia
journal, September 2016


Works referencing / citing this record:

Controlling current flow in sintering: A facile method coupling flash with spark plasma sintering
journal, January 2020


Pressure‐enhanced densification of TaC ceramics during flash spark plasma sintering
journal, September 2018


Reactive, nonreactive, and flash spark plasma sintering of Al 2 O 3 /SiC composites—A comparative study
journal, August 2019


Energy efficient spark plasma sintering: Breaking the threshold of large dimension tooling energy consumption
journal, September 2018


Simultaneous Spark Plasma Sintering of Multiple Complex Shapes
journal, February 2019


Figures/Tables have been extracted from DOE-funded journal article accepted manuscripts.