Spark plasma sintering and complex shapes: The deformed interfaces approach

Over the last few decades, the SPS technique has proven its benefits in terms of microstructure control, reduction of cycling time and a general stability of the results. However, to overcome the so-called “valley of death” between fundamental research and successful industrialization, the next step...

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Bibliographic Details
Published in:Powder technology 2017-10, Vol.320, p.340-345
Main Authors: Manière, Charles, Nigito, Emmanuel, Durand, Lise, Weibel, Alicia, Beynet, Yannick, Estournès, Claude
Format: Article
Language:English
Subjects:
Aluminum oxide
Chemical and Process Engineering
Compaction
Complex shape
Complexity
Control stability
Deformation
Densification
Engineering Sciences
Inhomogeneity
Interfaces
Materials
Microstructure
Plasma sintering
Plasmas
Polymethyl methacrylate
Polymethylmethacrylate
Powder compaction
Sacrificial material
Simulation
Spark plasma sintering
Valleys
Zirconium dioxide
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Summary:Over the last few decades, the SPS technique has proven its benefits in terms of microstructure control, reduction of cycling time and a general stability of the results. However, to overcome the so-called “valley of death” between fundamental research and successful industrialization, the next step is to prove the ability of this technology to perform the total densification of highly complex shape samples. The elaboration of complex shapes with die compaction processes often present densification inhomogeneity because of the thickness differences of the sample. In this paper, we present a method to solve this problem with an approach we called the “deformed interfaces method” that uses sacrificial materials. This method can be generalized to all the pressure assisted sintering techniques and allow a complete densification whatever the shape complexity of the part. This method is tested with different materials (Al, CoNiCrAlY, PMMA, Al2O3, 4Y-ZrO2) and shapes. To prove the effectiveness of this method on very high complex shapes, a 98% dense turbine blade shape has been made. [Display omitted] •An original approach to spark plasma sinter complex shapes has been developed.•A sacrificial material and a controlled interface deformation are exploited.•Complete densification is possible whatever the complexity of these shapes.•Fully dense, near net shape samples with high thickness differences are obtained.•A highly complex shape turbine blade has been fabricated using this approach.
ISSN:0032-5910
1873-328X
DOI:10.1016/j.powtec.2017.07.048