Spark plasma sintering of UO2 nanopowders: Pressure,heating rate and current effects

We analysed with different methods the densification of UO₂ nanopowders in SPS under constant heating rate (CHR) and isothermal sintering conditions. The apparent activation energy of densification in SPS (75 kJ/mol with CHR method) is significantly smaller than in conventional sintering. It is shown that this is likely not an effect of the applied current. We also observed a threshold stress at 64 MPa for the transition from pressure-insensitive sintering (stress exponent n≈0) to pressure-assisted sintering, suggesting that the contribution of the capillary stresses in such nanopowders is comparable with the typical stress applied in SPS.     

Hot‐Pressing Kinetics and Densification Mechanisms of Boron Carbide

The hot‐pressing kinetics of boron carbide at different stages in the hot‐pressing process was investigated. Based general densification equation and pore‐dragged creep model, the densification and grain growth kinetics were analyzed as a function of various parameters such as sintering temperature, sintering pressure and dwell time. Stress exponent of n ≈ 3 at the initial dwell stage suggests the plastic deformation may dominates the densification. The further TEM observations and the calculation based on effective stress and plastic yield stress also indicate that plastic deformation may occur and account for the large increase in density at the initial stage of sintering. Calculated grain size exponent of m ≈ 3 suggests that the grain‐boundary diffusion dominates the densification at the final stage. During the final stage of sintering, grain growth may be determined by evaporation/condensation and grain‐boundary migration.     

Rapid Grain Growth in 3Y‐TZP Nanoceramics by Pressure‐Assisted and Pressure‐Less SPS

Pressure‐less spark plasma sintering (SPS) is a new approach during which rapid densification of ceramic nanopowder green bodies is accompanied by rapid grain growth. Although the origin of this phenomenon has not yet been fully understood significant, difference in grain growth between pressure‐less and pressure‐assisted SPS was expected. In this work 3Y‐TZP nanopowder with average particle size of 12 nm was consolidated using two‐step approach: (1) at an intermediate temperature (600°C to 1000°C) SPS warm pressing followed by (2) high temperature (1400°C to 1600°C) pressure‐less SPS. The standard one step pressure‐assisted SPS experiments were quoted as references. Rapid grain growth was observed during both pressure‐less and standard SPS. The samples prepared by both approaches at the same sintering temperature (1400°C–1600°C) achieved identical grain size and grain size distribution, if large pores were eliminated in early stage by SPS warm pressing. The electric current, electromagnetic field, and mechanical pressure is proven to have a negligible direct influence on grain growth in 3Y‐TZP ceramics at temperatures above 1000°C under standard SPS conditions.     

Spark plasma sintered ZrC-Mo cermets: Influence of temperature and compaction pressure

The microstructure analysis and mechanical characterisation were performed on a ZrC-20 wt%Mo cermet that was spark plasma sintered at various temperatures ranging between 1600 and 2100 °C under either 50 or 100 MPa of compaction pressure. The composite reached ~98% relative density for all experiments with an average grain size between 1 and 3.5 µm after densification. The nature of SPS technology caused a faster densification rate when higher compaction pressures were applied. The difference in compaction pressures produced different behaviors in densification and grain structure: 1900 °C, 100 MPa produced excessive grain growth in ZrC; 1600 °C, 50 MPa revealed a very clear ZrC grain structure and Mo diffusion between carbide grains; and 2100 °C, 50 MPa exhibited the highest overall mechanical properties due to small clusters of Mo phases across the microstructure. In fact, this particular sintering regime gave the most optimal mechanical values: 2231 HV10 and 5.4 MPa*m^1/2, and 396 GPa Young's modulus. The compaction pressure of SPS played a pivotal role in the composites’ properties. A moderate 50 MPa pressure caused all three mechanical properties to increase with increasing sintering temperature. Conversely, a higher 100 MPa pressure caused fracture toughness and Young modulus to decrease with increasing sintering temperature.     

Effect of pressure and temperature on densification,microstructure and mechanical properties of spark plasma sintered silicon carbide processed with β-silicon carbide nanopowder and sintering additives

The effects of applied pressure and temperature during spark plasma sintering (SPS) of additive-containing nanocrystalline silicon carbide on its densification, microstructure, and mechanical properties have been investigated. Both relative density and grain size are found to increase with temperature. Furthermore, with increase in pressure at constant temperature, the relative density improves significantly, whereas the grain size decreases. Reasonably high relative density (~96%) is achieved on carrying out SPS at 1300 °C under applied pressure of 75 MPa for 5 min, with a maximum of ~97.7% at 1500 °C under 50 MPa for 5 min. TEM studies have shown the presence of an amorphous phase at grain boundaries and triple points, which confirms the formation of liquid phase during sintering and its significant contribution to densification of SiC at relatively lower temperatures (≤1400 °C). The relative density decreases on raising the SPS temperature beyond 1500 °C, probably due to pores caused by vaporization of the liquid phase. Whereas β-SiC is observed in the microstructures for SPS carried out at temperatures ≤1500 °C, α-SiC evolves and its volume fraction increases with further increase in SPS temperatures. Both hardness and Young׳s modulus increase with increase in relative density, whereas indentation fracture toughness appears to be higher in case of two-phase microstructure containing α and β-SiC.     

Microstructural evolution of ZnO via hybrid cold sintering/spark plasma sintering

In this work, we demonstrate a hybrid cold sintering/spark plasma sintering (CSP-SPS) process to densify ZnO ceramic with controlled grain growth. The densification of ZnO is initially activated at 85 °C, and high densities (>98%) are achieved at 200–300 °C in only 5 min with a low assisted pressure of 3.8–50 MPa. The microstructure of ZnO grains experiences a mild coarsening from ~205–680 nm during the CSP-SPS. In comparison, a much higher temperature (>770 °C) is required to sinter ZnO ceramic via SPS, and the grain size exhibits an obvious overgrowth to ~10 µm. The calculated apparent activation energy of grain growth using CSP-SPS is 69.3 ± 6 kJ/mol, which is much lower than that of SPS samples with 296.8 ± 59 kJ/mol. In addition, the conduction mechanism of the CSP-SPS and SPS samples is investigated using impedance spectroscopy. Overall, CSP-SPS is promising for the fabrication of fine ceramics with mild sintering conditions.     

Reactive FAST/SPS sintering of strontium titanate as a tool for grain boundary engineering

A high-pressure FAST/Spark Plasma Sintering method was used to produce dense SrTiO₃ ceramics at temperatures of 1050 °C, more than 250 °C below typical sintering temperatures. Combining SPS with solid-state reactive sintering further improves densification. The process resulted in fine-grained microstructures with grain sizes of ∼300 nm. STEM-EDS was utilized for analyzing cationic segregation at grain boundaries, revealing no cationic segregation at the GBs after SPS. Electrochemical impedance spectroscopy indicates the presence of a space charge layer. Space charge thicknesses were calculated according to the plate capacitor equation and the Mott-Schottky model. They fit the expected size range, yet the corresponding space charge potentials are lower than typical values of conventionally processed SrTiO₃. The low space charge potential was associated to low cationic GB segregation after SPS and likely results in better grain boundary conductivity. The findings offer a path to tailor grain boundary segregation and conductivity in perovskite ceramics.     

Densification mechanisms of UO2 consolidated by spark plasma sintering

Despite the growing interest in the spark plasma sintering (SPS) of uranium dioxide, its sintering mechanisms have yet to be studied in great detail. Herein we propose a direct method to calculate the apparent activation energy for densification, Q_act, and the stress exponent, n, for SPS of nearly stoichiometric UO₂. A set of experiments performed at different heating rates (CHR) and different pressures levels allowed us to calculate Q_act and n, respectively, though we were limited to a theoretical density between 50% to 75 %. The master sintering curve was employed as a complementary method to compare Q_act. The average values were Q_act =96 kJ/mol (CHR), Q_act = 100 kJ/mol (MSC) and n = 1.4. We have therefore proposed grain boundary diffusion coupled with grain boundary sliding as the densification mechanism. The activation energy in SPS tends to be lower compared with that in other processes like conventional sintering (250?450 kJ/mol), creep (350?550 kJ/mol) and hot pressing (222 kJ/mol and 480 kJ/mol).This decrease could be due to the effect of the electric field combined with the higher heating rates, typical of SPS.     

Densification of SiC by SPS-effects of time,temperature and pressure

Temperature, holding time and conditions of pressure application, three of the most important spark plasma sintering (SPS) parameters, have been reviewed to assess their effect on the densification and grain growth kinetics of a pure commercially available submicrometer-sized silicon carbide powder. Experiments were performed in the 1750–1850 °C temperature range with holding time from 1 to 10 min. Two pressure setups were used: one with pressure (75 MPa) applied at 1000 °C and the other with ultimate pressure applied at sintering temperature. Experimental data highlighted the fact that temperature and holding time have a different impact on grain growth and densification. Diffusion and migration mechanisms that promote grain growth were found to be strongly dependent on temperature, the latter being linked to pulsed current intensity. Conditions of pressure application suggest that the ultimate pressure applied at higher temperature increases densification by keeping small surface contact between particles.     

High‐Temperature Deformation Mechanisms in Monolithic 3YTZP and 3YTZP Containing Single‐Walled Carbon Nanotubes

Monolithic 3YTZP and 3YTZP containing 2.5 vol% of single‐walled carbon nanotubes (SWCNT) were fabricated by Spark Plasma Sintering (SPS) at 1250°C. Microstructural characterization of the as‐fabricated 3YTZP/SWCNTs composite shows a homogeneous CNTs dispersion throughout the ceramic matrix. The specimens have been crept at temperatures between 1100°C and 1200°C in order to investigate the influence of the SWCNTs addition on high‐temperature deformation mechanisms in zirconia. Slightly higher stress exponent values are found for 3YTZP/SWCNTs nanocomposites (n~2.5) compared to monolithic 3YTZP (n~2.0). However, the activation energy in 3YTZP (Q = 715 ± 60 kJ/mol) experiences a reduction of about 25% by the addition of 2.5 vol% of SWCNTs (Q = 540 ± 40 kJ/mol). Scanning electron microscopy studies indicate that there is no microstructural evolution in crept specimens, and Raman spectroscopy measurements show that SWCNTs preserved their integrity during the creep tests. All these results seem to indicate that the high‐temperature deformation mechanism is grain‐boundary sliding (GBS) accommodated by grain‐boundary diffusion, which is influenced by yttrium segregation and the presence of SWCNTs at the grain boundary.     

Rapid sintering of nanocrystalline ZrO2(3Y) by spark plasma sintering

SPS (spark plasma sintering) process was used to sinter nanocrystalline ZrO₂ (3Y). It was found to be different with the usual rapid sintering method, the density of the samples kept increasing with the rising of the sintering temperature. A higher density could be reached at a lower temperature and shorter dwelling time than that by hot-pressing under the similar pressures. In contrast to the samples with a differential densification from edge to center prepared by a rapid hot-pressing, no obvious densification gradient could be found in the samples sintered by SPS. The grain sizes of the Y-TZP obtained by SPS were smaller than those by the pressureless sintering method, while the grain growth speed was much higher under SPS conditions. All these unique sintering behaviors were explained by the special sintering process of SPS.     

Densification of nanocrystalline Y2O3 ceramic powder by spark plasma sintering

Nanocrystalline Y₂O₃ powders with 18 nm crystallite size were sintered using spark plasma sintering (SPS) at different conditions between 1100 and 1600 °C. Dense specimens were fabricated at 100 MPa and 1400 °C for 5 min duration. A maximum in density was observed at 1400 °C. The grain size continuously increased with the SPS temperature into the micrometer size range. The maximum in density arises from competition between densification and grain growth. Retarded densification above 1400 °C is associated with enhanced grain growth that resulted in residual pores within the grains. Analysis of the grain growth kinetics resulted in activation energy of 150 kJ mol^?1 and associated diffusion coefficients higher by 10³ than expected for Y³⁺ grain boundary diffusion. The enhanced diffusion may be explained by combined surface diffusion and particle coarsening during the heating up with grain boundary diffusion at the SPS temperature.     

Consolidation and high-temperature strength of monolithic lanthanum hexaboride

In this study we explored the densification, microstructure evolution, and high-temperature properties of bulk lanthanum hexaboride. LaB₆ bulks were consolidated using spark-plasma sintering only in the temperature range between 1400°C and 1700°C. We adopted flash spark plasma sintering (SPS) of LaB₆ using a direct current heating without a graphite die. We observed a peculiar grain-size gradient when coarse grains exceeding 300 μm were observed on the top side of the specimen, while the bottom side had a grain size of 15–20 μm. Such large grain was not observed using SPS at 2000°C, suggesting that these might originate from a local overheating. Based on the three-point flexural tests, it was observed that the toughness and strength of the LaB₆ were acceptable at room-temperature (3.1 ± 0.2 MPa m^1/2, 300 ± 20 MPa). However, at 1600°C, these parameters would decrease to 1.3 ± 0.1 MPa m^1/2 and 120 ± 40 MPa, respectively.     

Study of densification mechanisms during Spark Plasma Sintering of co-precipitated Ho:Lu2O3 nanopowders: Application to transparent ceramics for lasers

This work was focused on the determination of densification mechanisms during Spark Plasma Sintering (SPS) of Ho:Lu₂O₃ nanopowders. Strong variation of the stress exponent n was evidenced during the sintering process. At low relative density (i.e. ρ < 66 %), n = 3 and powder particles rearrangement and coalescence take place because of high value of effective stress and low size of primary nanoparticles. Then, for ρ between 66 % and 85 %, the stress exponent decreases to n = 2 then n = 1. Such values were related to Rachinger then Lifshitz sliding mechanisms, the last one was associated with an average activation energy of 565 kJ.mol⁻¹. At the final densification stage (ρ > 85 %), the stress exponent suddenly increases to 4 in accordance with a power-law creep. From these investigations, an optimized thermomechanical cycle was proposed to obtain highly transparent Ho:Lu₂O₃ ceramics suitable for laser applications.     

The effect of SPS parameters on the production of yttria transparent ceramic

In this work, the spark plasma sintering (SPS) of commercial yttria nanopowder is investigated. The SPS parameters such as sintering temperature, applied pressure, and dwell time are varied. Densification without grain growth occurring at occurred up to a sintering temperature of 1400°C and grain growth without further densification taking place at the higher temperature. The optimum sample was obtained at a temperature of 1400°C with a pressure of 70 MPa and dwelling time of 15 minutes. The highest relative density of 99.8% and the average grain size of 1.26 μm were obtained at 1400°C. The yttria ceramic annealed at 1200°C had the in-line transmission of 5%-70% and 70%-82% in the visible and infrared wavelength region, respectively. The measurements of hardness and fracture toughness characteristics of the transparent yttria ceramic showed 9.2 GPa and 2.24 MPa.m^1/2, respectively.     

Transparent yttrium aluminum garnet (YAG) ceramics by spark plasma sintering

Commercial nanocrystalline yttrium aluminum garnet (nc-YAG) powders were used for fabrication of dense and transparent YAG by spark plasma sintering (SPS). Spherical 34 nm size particles were densified by SPS between 1200 and 1500 °C using 50 and 100 MPa pressures for 3, 6, and 9 min durations. Fully dense and transparent polycrystalline cubic YAG with micrometer grain size were fabricated at very moderate SPS conditions, i.e. 1375 °C, 100 MPa for 3 min. Increase in the SPS duration and pressure significantly increased the density especially at the lower temperature range. The observed microstructure is in agreement with densification by nano-grain rotation and sliding at lower densities, followed by curvature driven grain boundary migration and normal grain growth at higher densities. Residual nanosize pores at the grain boundary junctions are an inherent microstructure feature due to the SPS process.     

Microstructure and mechanical properties of (Ti,W)C cermets prepared by ultrafast spark plasma sintering

To explore the impact of the sintering rate on the microstructure and mechanical properties of cermets, the preparation of (Ti,W)C cermets by ultrafast sintering via spark plasma sintering (SPS) is reported. Compared with a slow heating rate, the electric field produced by an ultrafast heating rate enhances the liquid phase mass transfer of the metal binder phase, thus achieving rapid densification of (Ti,W)C cermets and effectively inhibiting abnormal grain growth. However, an excessive heating rate will lead to an “overflow” phenomenon, which reduces the grain growth difficulty and the bonding strength between grains. The results show that when the heating rate is 500 °C/min, the liquid phase mass transfer is moderate, the densification degree is the highest and the mechanical properties are excellent. The flexural strength, Vickers hardness and fracture toughness are 1340.90 ± 23.55 MPa, 18.42 ± 0.46 GPa and 11.96 ± 0.23 MPa?m^1/2, respectively.     

High-temperature compressive creep of spark-plasma sintered additive-free polycrystalline β-SiC

The high temperature mechanical behaviour of additive-free nano-size power of β-SiC sintered by spark-plasma sintering (SPS) technique has been studied. Samples had a mean grain size of 0.58 μm and 97.4% of relative density. They were deformed by means of constant load compression (creep) tests at temperatures between 1750 and 1850 °C and stresses between 200 and 500 MPa. The strain rates ranged from 1 × 10^?7 s^?1 to 1 × 10^?6 s^?1 depending on the test conditions. The activation energy Q and the stress exponent n parameters, which characterize the deformation mechanisms, were evaluated. The values obtained for the activation energy Q in the whole temperature range was 540 kJ mol^?1, and the stress exponent n values were between 1.2 and 1.3 for T = 1750 °C and 2.6 for T = 1800 °C. The values of these parameters, together with the results of microscopy of the deformed samples, suggested that there are two mechanisms operating simultaneously: (i) grain boundary sliding (GBS) accommodated by diffusion of Si along the grain boundary and (ii) dislocation glide and climb (power law creep (PLC)). The contribution of the latter mechanism increases with temperature.     

Studies on ionic conductivity of stabilized zirconia ceramics (8YSZ) densified through conventional and non-conventional sintering methodologies

Densification studies of 8 mol% yttria stabilized zirconia ceramics were carried out by employing the sintering techniques of conventional ramp and hold (CRH), spark plasma sintering (SPS), microwave sintering (MWS) and two-stage sintering (TSS). Sintering parameters were optimized for the above techniques to achieve a sintered density of >99% TD. Microstructure evaluation and grain size analysis indicated substantial variation in grain sizes, ranging from 4.67 μm to 1.16 μm, based on the sintering methodologies employed. Further, sample was also sintered by SPS technique at 1425 °C and grains were intentionally grown to 8.8 μm in order to elucidate the effect of grain size on the ionic conductivity. Impedance spectroscopy was used to determine the grain and grain boundary conductivities of the above specimens in the temperature range of RT to 800 °C. Highest conductivity of 0.134 S/cm was exhibited by SPS sample having an average grain size of 1.16 μm and a decrease in conductivity to 0.104 S/cm was observed for SPS sample with a grain size of 8.8 μm. Ionic conductivity of all other samples sintered vide the techniques of TSS, CRH and MWS samples was found to be ∼0.09 S/cm. Highest conductivity irrespective of the grain size of SPS sintered samples, can be attributed to the low densification temperature of 1325 °C as compared to other sintering techniques which necessitated high temperatures of ∼1500 °C. The exposure to high temperatures while sintering with TSS, CRH and MWS resulted into yttria segregation leading to the depletion of yttria content in fully stabilized zirconia stoichiometry as evidenced by Energy Dispersive Spectroscopy (EDS) studies.     

The influence of MgO,Y2O3 and ZrO2 additions on densification and grain growth of submicrometre alumina sintered by SPS and HIP

Spark plasma sintering followed by hot isostatic pressing was applied for preparation of polycrystalline alumina with submicron grain size. The effect of additives known to influence both densification and grain growth of alumina, such as MgO, ZrO₂ and Y₂O₃ on microstructure development was studied. In the reference undoped alumina the SPS resulted in some microstructure refinement in comparison to conventionally sintered materials. Relative density >99% was achieved at temperatures >1200 °C, but high temperatures led to rapid grain growth. Addition of 500 ppm of MgO, ZrO₂ and Y₂O₃ led, under the same sintering conditions, to microstructure refinement, but inhibited densification. Doped materials with mean grain size <400 nm were prepared, but the relative density did not exceed 97.9%. Subsequent hot isostatic pressing (HIP) at 1200 and 1250 °C led to quick attainment of full density followed by rapid grain growth. The temperature of 1250 °C was required for complete densification of Y₂O₃ and ZrO₂-doped polycrystalline alumina by HIP (relative density >99.8%), and resulted in fully dense opaque materials with mean grain size<500 nm.