Effect of sintering process on the microstructures and properties of in situ TiB2–TiC reinforced steel matrix composites produced by spark plasma sintering

Spark plasma sintering (SPS) is a new technique to rapidly produce metal matrix composites (MMCs), but there is little work on the production of TiB₂–TiC reinforced steel matrix composites by SPS. In this work, in situ TiB₂–TiC particulates reinforced steel matrix composites have been successfully produced using cheap ferrotitanium and boron carbide powders by SPS technique. The effect of sintering process on the densification, hardness and phase evolution of the composite is investigated. The results show that when the composite is sintered at 1050 °C for 5 min, the maximum densification and hardness are 99.2% and 83.8 HRA, respectively. The phase evolution of the composite during sintering indicates that the in situ TiB₂–TiC reinforcements are formed by a hybrid formation mechanism containing solid–solid diffusion reaction and solid–liquid solution-precipitation reaction. The microstructure investigation reveals that fine TiB₂–TiC particulates with a size of ～2 μm are homogeneously distributed in the steel matrix. The TiB₂–TiC/Fe composites possess excellent wear resistance under the condition of dry sliding with heavy loads.     

Influence of SPS parameters on the density and mechanical properties of sintered Ti3SiC2 powders

The densification of Ti₃SiC₂ MAX phase was performed by the Spark Plasma Sintering (SPS) technique. The SPS parameters, such as sintering temperature, pressure and soaking time, were optimized to obtain fully densified samples which were characterized to obtain the best mechanical properties. The sintering temperature was varied from 1070 to 1300 °C, the soaking time from 1 to 10 min and the applied pressure from 60 to 180 MPa. The best full densified samples were sintered at 1300 °C applying 60 MPa for 7 min. Ti_xC_y and TiSi₂ secondary phases were found in samples densified at 1200, 1250 and 1300 °C, due to decomposition of Ti₃SiC₂. These secondary phases, detected by XRD patterns, were confirmed by microhardness testing, FESEM observations and EDAX analyses.     

A study of the densification mechanisms during spark plasma sintering of zirconium (oxy-)carbide powders

Zirconium oxycarbide powders with controlled composition ZrC_0.94O_0.05 were synthesized using the carboreduction of zirconia. They were further subjected to spark plasma sintering (SPS) under several applied loads (25, 50, 100 MPa). The densification mechanism of zirconium oxycarbide powders during the SPS was studied. An analytical model derived from creep deformation studies of ceramics was successfully applied to determine the mechanisms involved during the final stage of densification. These mechanisms were elucidated by evaluating the stress exponent (n) and the apparent activation energy (E_a) from the densification rate law. It was concluded that at low macroscopic applied stress (25 MPa), an intergranular glide mechanism (n ? 2) governs the densification process, while a dislocation motion mechanism (n ? 3) operates at higher applied load (100 MPa). Transmission electron microscopy observations confirm theses results. The samples treated at low applied stress appear almost free of dislocations, whereas samples sintered at high applied stress present a high dislocation density, forming sub-grain boundaries. High values of apparent activation energy (e.g. 687–774 kJ mol^?1) are reached irrespective of the applied load, indicating that both mechanisms mentioned above are assisted by the zirconium lattice diffusion which thus appears to be the rate-limiting step for densification.     

Synthesis and characterization of Al2O3–TiC nano-composite by spark plasma sintering

Al₂O₃–10TiC composite was synthesized by high energy ball milling followed by spark plasma sintering (SPS) process. Microstructure of the sintered composite samples reveals homogeneous distribution of the TiC particles in Al₂O₃ matrix. Effect of sintering temperature on the microstructure and mechanical properties was studied. The sample sintered at 1500 °C shows a measured density of 99.97% of their theoretical density and hardness of 1892 Hv with very high scratch resistance. These results demonstrate that powder metallurgy combined with spark plasma sintering is a suitable method for the production of Al₂O₃–10TiC composites.     

Investigation of thermoelectric properties of Cu2GaxSn1 − xSe3 diamond-like compounds by hot pressing and spark plasma sintering

P-type compounds Cu₂Ga_xSn_1 ? xSe₃ (x = 0.025, 0.05, 0.075) with a diamond-like structure were consolidated using hot pressing sintering (HP) and spark plasma sintering (SPS) techniques. High-temperature thermoelectric properties as well as low-temperature Hall data are reported. Microstructural analysis shows that the distribution of Ga is homogeneous in the samples sintered by HP but inhomogeneous in the samples sintered by SPS, even with an electrically isolating and thermally conducting BN layer during the sintering. The Seebeck coefficients of the samples sintered by HP and SPS show similar dependence on the carrier concentration and are insensitive to the composition inhomogeneity. In contrast, the composition inhomogeneity results in lower carrier mobility and thus lower electrical conductivity in the samples sintered by SPS than those sintered by HP. Lattice thermal conductivity is further reduced through Ga doping; however, this effect is weakened by the inhomogeneous distribution of Ga. Due to their larger carrier mobility and lower lattice thermal conductivity, the samples sintered by HP exhibit 15–35% higher thermoelectric figure of merits (ZT) than those SPS samples with a high Ga doping level and without the coated BN layer, in which the composition homogeneity is worse. A ZT value of 0.43 is obtained for the HP Cu₂Ga_0.075Sn_0.925Se₃ sample at 700 K.     

Effect of ball-milling time on structural characteristics and densification behavior of W-Cu composite powder produced from WO3-CuO powder mixtures

Understanding the microstructure of W–Cu nanocomposite powder is essential for elucidating its sintering mechanism. In this study, the effect of milling time on the structural characteristics and densification behavior of W-Cu composite powders synthesized from WO₃-CuO powder mixtures was investigated. The mixture of WO₃ and CuO powders was ball-milled in a bead mill for 1 h and 10 h followed by reduction by heat-treating the mixture at 800 °C in H₂ atmosphere with a heating rate of 2 °C/min to produce W-Cu composite powder. The microstructure analysis of the reduced powder obtained by milling for 1 h revealed the formation of W–Cu powder consisting of W nanoparticle-attached Cu microparticles. However, Cu-coated W nanocomposite powder consisting of W nanoparticles coated with a Cu layer was formed when the mixture was milled for 10 h. Cu-coated W nanopowder exhibited an excellent sinterability not only in the solid-phase sintering stage (SPS) but also in the liquid-phase sintering stage (LPS). A high relative sintered density of 96.0% was obtained at 1050 °C with a full densification occurring on sintering the sample at 1100 °C. The 1 h-milled W-Cu powder exhibited a high sinterability only in the LPS stage to achieve a nearly full densification at 1200 °C.     

Fe–B–C composites produced using spark plasma sintering

Fe–B–C composites were produced using iron and boron carbide powders. The powders were mixed to produce various compositions, ranging from 1 vol.% Fe to 80.1 vol.% Fe. Spark plasma sintering (SPS) was used to densify the composite powder green compacts. The sintering temperatures used ranged from 900 °C for the composites with a high iron content to 2000 °C for those with a high boron carbide content. It was evident that during the sintering process the iron reacted with the boron carbide. XRD analysis showed the presence of FeB, Fe₂B, Fe₃C, Fe₃(B_0.6C_0.4), Fe₂₃(B,C)₆ and residual carbon as reaction products. The composites were found to have hardness values between 9.8 and 33.1 GPa with the higher hardness being associated with the higher boron carbide contents. The fracture toughness values determined were in the range of 2.8–5.3 MPa m^0.5. With increasing iron content from 1 to 5 vol.%, it is evident that the FeB formed begins to embrittle the material rather than increase the fracture toughness as a result of the high residual stresses between the B₄C and FeB phases.     

A study on mechanochemical behavior of MoO3–Mg–C to synthesize molybdenum carbide

The influence of Mg value in the MoO₃–Mg–C mixture on the molybdenum carbide formation and the mechanism of reactions during mechanochemical process were investigated. In keeping with this aim, magnesium and carbon contents of the mixture were changed according to the following reaction: 2MoO₃ + (6 − x) Mg + (1 + x) C = (6 − x) MgO + Mo₂C + x CO. The value of x varied from 0 to 6. Differential thermal analysis (DTA) results for sample with stoichiometric ratio (x = 0) revealed that in the early stage, carbon reduced the MoO₃ to MoO₂ and subsequently highly exothermic magnesiothermic MoO₂ reduction occurred after magnesium melting. Also, it was indicated that the exothermic reaction temperature shifted to before magnesium melting in the 11 h-milled sample (x = 0) and all the exothermic reactions happened, simultaneously. According to the experimental findings, molybdenum carbide (Mo₂C) was synthesized in the mixture powder with stoichiometric ratio (x = 0) after 12 h milling process and the type of reactions was mechanically induced self-sustaining reaction (MSR). However, at lower Mg content in the MoO₃–Mg–C mixture (0 < x ≤ 2), the magnesiothermic reduction occurred in MSR mode and activated the carbothermal reaction. Further decrease in Mg value (2 < x ≤ 3) resulted in MSR mode magnesiothermic reaction and gradual carbothermal reduction. In samples with lower magnesium contents, partial molybdenum oxide reduction proceeded through a gradual mode magnesiothermic reaction.     

Spark plasma sintering of (Ti0.9W0.1) C powders prepared by mechanical alloying

Nanocrystalline (Ti_0.9W_0.1)C powder with a diffraction crystallite size of about 10 nm was synthesized by mechanical alloying. The formation of (Ti_0.9W_0.1)C carbide was detected by XRD measurements and microscopic observation. The sintering of these powders by a spark plasma sintering (SPS) at different temperatures were also studied. The results show that the maximum hardness was obtained for more relative density materials, meanwhile, the grain size is large. The micro-hardness and the relative density of the powder milled for 10 h and sintered at 1200 °C for 5 min under 100 MPa reach, respectively, 2978 HV and 98.35%.     

Effect of Al addition on SiC–B4C cermet prepared by pressureless sintering and spark plasma sintering methods

SiC–B₄C–Al cermets containing 5, 10 and 20 wt.% of Al were fabricated by high-energy planetary milling followed by conventional sintering and spark plasma sintering (SPS) techniques separately. The average particle size reduced to ~ 3 μm from an initial size of 45 μm after 10 h of milling. The as-milled powders were conventionally sintered at 1950 °C for 30 min under argon atmosphere and SPS was carried out at 1300 °C for 5 min under 50 MPa applied pressure. The formation of Al₈B₄C₇ and AlB₁₂ phases during conventional sintering and SPS were confirmed by X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses. The formation of Al₈B₄C₇ at 700 °C and AlB₁₂ at 1000 °C was well supported by XRD and differential scanning calorimetry (DSC). The maximum relative density, microhardness and indentation fracture resistance of SiC–B₄C–10Al consolidated by SPS are 97%, 23.80 GPa and 3.28 MPa·m^1/2, respectively.     

Spark plasma sintering of a commercially available granulated zirconia powder: Comparison with hot-pressing

A commercially available granulated TZ3Y powder has been sintered by hot-pressing (HP). The “grain size/relative density” relationship, referred to here as the “sintering path”, has been established for a constant value of the heating rate (25 °C min^?1) and a constant value of the macroscopic applied pressure (100 MPa). It has then been compared to that obtained previously on the same powder but sintered by spark plasma sintering (SPS, heating rate of 50 °C min^?1, same applied macroscopic pressure). By coupling the analysis of a sintering law (derived from creep rate equations) and comparative observations of sintered samples using transmission electron microscopy, a hypothesis about the densification mechanism(s) involved in SPS and HP has been proposed. Slight differences in the densification mechanisms lead to scars in the microstructure that explain the higher total ionic conductivity measured, in the temperature range 300–550 °C, when SPS is used for sintering.     

Densification and grain growth during early-stage sintering of Ce0.9Gd0.1O1.95−δ in a reducing atmosphere

The present work investigates the processes of densification and grain growth of Ce_0.9Gd_0.1O_1.95?δ (CGO10) during sintering under reduced oxygen partial pressure. Sintering variables were experimentally characterized and analyzed using defect chemistry and sintering constitutive laws. Based on the results achieved, the grain size–relative density relationship, the densification rate and the grain-growth rate were determined. The activation energies for densification and grain growth were evaluated, and the dominant densification mechanism was indicated. For comparison, the densification behavior of CGO10 sintered in air was also studied. Accelerated densification was observed in early-stage sintering of CGO10 in a reducing atmosphere. This might be attributed to the oxygen vacancies generated by the reduction of Ce⁴⁺ to Ce³⁺ in the reducing atmosphere, which facilitate the diffusion of ions through the lattice. The densification activation energy of CGO10 in the reducing atmosphere was evaluated to be 290 ± 20 kJ mol^?1 in the relative density range of 0.64–0.82, which was much smaller than that of CGO10 sintered in air (770 ± 40 kJ mol^?1). The grain-growth activation energy of CGO10 sintered in the reducing atmosphere was evaluated to be 280 ± 20 kJ mol^?1 in the grain size range of 0.34–0.70 μm. The present work describes a systematic investigation of sintering behavior of CGO10 under reduced oxygen partial pressure, which contributes to the first known determination of the fundamental parameters associated with densification and grain growth during early-stage sintering of CGO10 in a reducing atmosphere.     

Oxidation behavior of micro-sized Al2O3–TiC–Co composites prepared from cobalt-coated powders

The oxidation behavior of hot-pressed Al₂O₃–TiC–Co composites prepared from cobalt-coated powders has been studied in air in the temperature range from 200 °C to 1000 °C for 25 h. The oxidation resistance of Al₂O₃–TiC–Co composites increases with the increase of sintering temperature at 800 °C and 1000 °C. The oxidation surfaces were studied by XRD and SEM. The oxidation kinetics of Al₂O₃–TiC–Co composites follows a rate that is faster than the parabolic-rate law at 800 °C and 1000 °C. The mechanism of oxidation has been analyzed using thermodynamic and kinetic considerations.     

Processing,phase evaluation and mechanical properties of MoSi2 doped 4TaC–HfC based UHTCs consolidated by spark plasma sintering

In this research, binary 4TaC–HfC based composites were consolidated using carbide materials and addition of 0–15 vol.% MoSi₂ by means of spark plasma sintering at 2000 °C. The nearly full dense and monophase specimens were fabricated with a relative density value higher than 99%. Mechanical tests revealed values of 18–19 GPa and 4–4.3 MPa·m^1/2, for average Vickers hardness and fracture toughness of the composites, respectively. Analysis of linear shrinkage during densification revealed that MoSi₂ addition increased densification rate and decreased the time required to reach full density at 2000 °C. It is proposed that at the intermediate stage of sintering, mass transfer can be accelerated by formation of a silicide based liquid phase and viscous flow mechanisms. The formation of binary 4TaC–HfC solid solution phase enhanced the densification process at the final stage of sintering.     

Spark plasma sintering of pure TiCN: Densification mechanism,grain growth and mechanical properties

This study aims to disclose the densification mechanism and grain growth behaviors during the spark plasma sintering (SPS) of undoped TiCN powder. The SPS experiments were performed under temperatures ranging from 1600 °C to 2200 °C and a fixed pressure of 50 MPa. The sintering mechanisms were described in different models according to two grain growth behaviors: densification without grain growth at low temperatures (1600–1700 °C) and grain growth without apparent densification at higher temperatures (1800–2200 °C). At the constant grain stage, a creep model is applied to describe the densification process. In addition, the effective stress exponents, n, are calculated, indicating that the densification can be attributed to both grain boundary sliding (n = 1.5) and dislocation climbing (n = 3.13 or n = 4.29). During the second stage of sintering, the grain growth model reveals that the grain-growth is controlled by grain boundary diffusion. In addition, the Vickers hardness varies from 4326 Hv to 6762 Hv when the density ranges from 90% to 96.3%.     

Effect of pressure on combustion synthesis of TiC/Fe-Cu composites under the action of electric current

Using electric-current-assisted combustion synthesis (ECACS) in a Gleeble thermal simulation instrument, composites of TiC/Fe-Cu have been in-situ synthesized directly from elemental powders of iron, copper, titanium and graphite. This study was focused on the effect of pressure on the combustion synthesis of TiC/Fe-Cu composites and the properties of TiC/Fe-Cu composites. With the aid of a high electric current, a relatively low onset temperature for the combustion reaction, between 747 °C and 768 °C, could be achieved. The ignition temperature decreased with the increase of the pressure in the heating process. The final products of samples were composed of Fe, Cu, TiC and the pressure had little influence on the phase composition. All the titanium carbide particles were fine and in a range of about 0.2 μm–0.35 μm. When the pressure increased, the density and microhardness of sample increased, so the wear resistance improved.     

Direct comparison between hot pressing and electric field-assisted sintering of submicron alumina

This study compares hot pressing (HP) and the electric field-assisted sintering technique (FAST) of two different electrically insulating Al₂O₃ submicron powders with median particle sizes of 150 and 500 nm. Sample geometry, heating schedule, applied pressure and atmosphere were identical for both sintering methods. The densification behavior and characterization of the microstructure revealed that FAST sintered samples reached a higher density compared with HP, in particular for the finer powder. It was found that an increase in dwell time was required to reach the same final density by HP. However, analysis of the sintering curves showed that the densification mechanism for both sintering methods was grain boundary diffusion. Increasing the heating rate up to 150 K min^?1 did not modify the densification mechanism. The sintering trajectory showed that the grain size was only dependent on density and was insensitive to the sintering method, in addition to showing a lack of preferential grain orientation.     

Effect of Mo2C additions on the properties of SPS manufactured WC–TiC–Ni cemented carbides

The effect of spark plasma sintering (SPS) on the microstructure and mechanical properties of WC–Co and WC–Ni cemented carbides was studied, and compared to WC–Co produced by liquid phase sintering (LPS). There were finer WC grains with larger Co pools in the spark plasma sintered WC–Co, resulting in higher hardness and slightly lower fracture toughness than the liquid phase sintered WC–Co. The influence of the addition of 0.5–5 wt.%Mo₂C to WC-based cemented carbide containing 6.25 wt.%TiC and 9.3 wt.%Ni prepared by SPS was also studied. This addition improved the wettability between WC and Ni and lead to the improvements of microstructures, resulting in good combinations of hardness, fracture toughness and modulus of elasticity that were comparable to WC–Co based cemented carbides.     

Application of a novel microwave plasma treatment for the sintering of nickel oxide coatings for use in dye-sensitized solar cells

In this study the use of microwave plasma sintering of nickel oxide (NiO_x) particles for use as p-type photoelectrode coatings in dye-sensitized solar cells (DSSCs) is investigated. NiO_x was chosen as the photocathode for this application due to its stability, wide band gap and p-type nature. For high light conversion efficiency DSSCs require a mesoporous structure exhibiting a high surface area. This can be achieved by sintering particles of NiO_x onto a conductive substrate. In this study the use of both 2.45 GHz microwave plasma and conventional furnace sintering were compared for the sintering of the NiO_x particles. Coatings 1 to 2.5 μm thick were obtained from the sintered particles (mean particle size of 50 nm) on 3 mm thick fluorine-doped tin oxide (FTO) coated glass substrates. Both the furnace and microwave plasma sintering treatments were carried out at ~ 450 °C over a 5 min period. Dye sensitization was carried out using Erythrosin B and the UV–vis absorption spectra of the NiO_x coatings were compared. A 44% increase in the level of dye adsorption was obtained for the microwave plasma sintered samples as compared to that obtained through furnace treatments. While the photovoltaic performance of the DSSC fabricated using the microwave plasma treated NiO_x coatings exhibited a tenfold increase in the conversion efficiency in comparison to the furnace treated samples. This enhanced performance was associated with the difference in the mesoporous structure of the sintered NiO_x coatings.     

Fabrication and soft-magnetic properties of Fe–B–Nb–Y glassy powder compacts by spark plasma sintering technique

Magnetic properties of (Fe_0.72B_0.24Nb_0.04)_95.5Y_4.5 sample were investigated. The sample was produced from glassy powders made by the gas-atomization and consolidation using the spark plasma sintering (SPS) technique. Maximum relative density of 99.5% was achieved in the spark plasma sintered (SPSed) compact due to the viscous flow enhanced by the applied stress even under the glass transition temperature. X-ray diffraction pattern of the compact indicates that the glassy structure was maintained through the SPS process. However, the results of differential scanning calorimetry (DSC) showed that the glass transition temperature and crystallization temperature of the SPSed glassy compact shift to a higher and lower temperature, respectively, that is, a smaller ΔT_x. Saturation magnetization of the SPSed glassy compact became 10% higher than that of the initial glassy powder. The Curie point was enhanced from 522 K for the glassy powder to 548 K for the SPSed glassy compact. Spin-exchange interaction is expected to be enhanced by a short-range scale atomic rearrangement caused by the high applied stress and temperature during the SPS process.