Spark plasma sintering

Spark plasma sintering (SPS),[1] also known as field assisted sintering technique (FAST)[2] or pulsed electric current sintering (PECS), or plasma pressure compaction (P2C)[3] is a sintering technique.

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The main characteristic of SPS is that the pulsed or unpulsed DC or AC current directly passes through the graphite die, as well as the powder compact, in case of conductive samples. Joule heating has been found to play a dominant role in the densification of powder compacts, which results in achieving near theoretical density at lower sintering temperature compared to conventional sintering techniques.[4] The heat generation is internal, in contrast to the conventional hot pressing, where the heat is provided by external heating elements. This facilitates a very high heating or cooling rate (up to 1000 K/min), hence the sintering process generally is very fast (within a few minutes). The general speed of the process ensures it has the potential of densifying powders with nanosize or nanostructure while avoiding coarsening which accompanies standard densification routes. This has made SPS a good method for preparation of a range of materials with enhanced magnetic,[5] magnetoelectric,[6] piezoelectric,[7] thermoelectric,[8] optical[9] or biomedical[10] properties. SPS is also used for sintering of carbon nanotubes[11] for development of field electron emission electrodes. Functioning of SPS systems is schematically explained in a video link.[12] While the term "spark plasma sintering" is commonly used, the term is misleading since neither a spark nor a plasma is present in the process.[13] It has been experimentally verified that densification is facilitated by the use of a current. SPS can be used as a tool for the creation of functionally graded soft-magnetic materials and it is useful in accelerating the development of magnetic materials.[14] It has been found that this process improves the oxidation resistance [15] and wear resistance[16] of sintered tungsten carbide composites compared to conventional consolidation methods.

A kind of sintering that involves both temperature and pressure

Hybrid heating

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By means of a combination of the FAST/SPS method with one or several additional heating systems acting from the outside of the pressing tool systems it's possible to minimize the thermal gradients thus allowing the enhancement of the heating rates at simultaneously optimized homogeneity.[citation needed]

In 2012 the world's largest hybrid SPS-hot press sintering system was set up in Spain[17] and the fabrication of fully dense large ceramic blanks of up to 400mm with this system is in progress within the frame of the FP7 European Project HYMACER - Hybrid sintering and advanced machining of technical ceramics

Spark plasma sintering, also known as plasma pressure compaction (P2C) sintering, equipment are commercially available now and are no longer limited to laboratory research work. Products like body armor, rocket nozzles, carbon fiber composites and several other hybrid materials can be produced in commercial scale using these equipment.[18]

See also

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• Electric current assisted sintering – Process of forming and bonding material by heat or pressure

References

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As the first US OEM for Spark Plasma Sintering (SPS)/Direct Current Sintering (DCS) press furnace systems, Thermal Technology LLC has advanced this rapid processing technology to its furthest possibilities for lab and commercial scale use. Applications include metals, ceramics, composites, and diffusion bonding. These product lines are Top Tier systems which span from 5 to 800 tons and beyond.

What is Spark Plasma Sintering

The Direct Current Sintering furnace is Thermal Technology’s product offering for the process known as Spark Plasma Sintering (SPS) or the Field Assisted Sintering Technique (FAST). The process uses high electrical current to rapidly heat a conductive tooling assembly under simultaneous uniaxial pressure inside of a vacuum chamber. With no heating elements extremely rapid heating and cooling of the sample is possible, enabling high density materials to be sintered with ultra-fine or even nano-sized grain structures. The rapid precisely controlled high temperature coupled with high applied force in the sintering process creates a high density material needed for special applications not obtainable with other processes.

Our Direct Current Sintering furnaces are used in both research and development as well as industry of specialized materials. They can be found in national labs and universities to manufacturers around the world on the cutting edge of their industry.

The Process

All Direct Current Sintering furnaces feature state of the art compact power supplies to deliver the high currents required for rapid heating. Our standard units have a maximum temperature of 2,500°C. Laboratory units (DCS 10 and 25) are equipped with pulsed and continuous DC power capabilities as standard. Larger industrial units operate with continuous DC as standard and pulsed DC available as an option. All systems feature an easy to use touchscreen interface and state of the art hydraulic controls for fully automatic operation.

The sintering system is also upgradeable with a variety of options, including; gas-quenching for rapid cooling, glovebox integration for hazardous materials, and high-vacuum pumps. Our sales team can answer any questions and help you determine the right system for your specific application. Send us an inquiry to be connected with an appropriate sales team member

The DCS process allows rapid heating of materials with applied pressure within a conductive die assembly that is processed within a vacuum chamber.

Standard DCS Product Features

• Maximum temperature: 2,500°C (limited by part size).
• Vacuum (10^-3 Torr range) and Inert gas (Ar, He, N2) operation.
• 10 Volts for heating power (Higher voltages available).
• Fully automatic operation by PLC and touchscreen HMI.
• Programmable heating rates to 1,000°C or higher.
• Thermocouple and Pyrometer based temperature control.
• On the fly switching between current and temperature control.
• Rapid vacuum cycling: typical <10min
• Water flow and pressing ram overtemperature system protection

Direct Current Sintering Furnace Product Examples

DCS10

DCS25

DCS50

DCS100/DCS200

DCS500/DCS800

Standard Direct Current Sintering Furnace Equipment

ModelForce kN (Tons)Heating CurrentTypical Part Size mm (inch)DCS 10100kN (10.2T)5,000A*10-50mm (0.4-2″)DCS 25250kN (25.4T)10,000A*10-100mm (0.4-4″)DCS 50500kN (51T)20,000A30-150mm (1.5-6″)DCS 1001,000kN (102T)30,000A50-200mm (2-8″)DCS 2002,000kN (204T)50,000A50-300mm (2-12″)DCS 500 5,000kN (510.2 Ton)150,000A100mm-560mm (4”-22”)DCS 8008,000kN (815.8 Ton)150,000A100mm-560mm (4”-22”)

*Pulse DC capable power supply standard.

Note: Maximum part size will be dependent on target temperature. Inquire within for more details.

Larger Models Available. Contact for Details.

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Standard Product Features

• Maximum Pressing Temperature: 2,500°C
• Vacuum (10^-3 Torr range) and Inert gas (Ar, He, N2) operation.
• Fully automatic operation by PLC and touchscreen HMI.
• Simultaneous temperature and pressure control.
• Thermocouple and Pyrometer based temperature control.
• Rapid vacuum cycling: typical <10min
• Water flow and furnace overtemperature system protection

Common Optional Upgrades

• Increased throughput vacuum pump
• High vacuum pumps (Diffusion, Turbo, Cryo)
• Glovebox integration for reactive or hazardous materials
• Gas quenching systems for rapid cooling
• Combustible gas safety system (Hydrogen, Methane, ect.)

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