Spark Plasma Sintering of WC-Based 10wt%Co Hard Alloy: A Study of Sintering Kinetics and Solid-Phase Processes

The paper describes the method for producing WC-10wt%Co hard alloy with 99.6% of the theoretical density and a Vickers hardness of ~1400 HV 0.5. Experimental data on densification dynamics, phase composition, morphology, mechanical properties, and grain size distribution of WC-10%wtCo using spark plasma sintering (SPS) within the range of 1000–1200 °C are presented. The high quality of the product is provided by the advanced method of high-speed powder mixture SPS-consolidation at achieving a high degree of densification with minimal calculated grain growth at 1200 °C.     

Spark Plasma Sintering of Aluminum-Based Powders Reinforced with Carbon Nanotubes: Investigation of Electrical Conductivity and Hardness Properties

This paper focuses on reporting results obtained by the spark plasma sintering (SPS) consolidation and characterization of aluminum-based nanocomposites reinforced with concentrations of 0.5 wt%, 1 wt% and 2 wt% of single-walled carbon nanotubes (SWCNTs) and multi-walled carbon nanotubes (MWCNTs). Experimental characterization performed by SEM shows uniform carbon nanotube (CNT) dispersion as well as carbon clusters located in the grain boundary of the Al matrix. The structural analysis and crystallite size calculation were performed by X-ray diffraction tests, detecting the characteristic CNT diffraction peak only for the composites reinforced with MWCNTs. Furthermore, a considerable increment in the crystallite size value for those Al samples reinforced and sintered with 1 wt% of CNTs was observed. Hardness tests show an improvement in the composite surface hardness of about 11% and 18% for those samples reinforced with 2 wt% of SWNCTs and MWCNTs, respectively. Conductivity measurements show that the Al samples reinforced with 2 wt% of MWCNTs and with 0.5 wt% SWCNTs reach the highest IACS values of 50% and 34%, respectively.     

Mechanical and Tribological Behavior of Mechanically Alloyed Ni-TiC Composites Processed via Spark Plasma Sintering

Titanium carbide (TiC) reinforced nickel (Ni) matrix composites were processed via mechanical alloying (MA) followed by spark plasma sintering (SPS) process. Mechanical alloying has gained special attention as a powerful non-equilibrium process for fabricating amorphous and nanocrystalline materials, whereas spark plasma sintering (SPS) is a unique technique for processing dense and near net shape bulk alloys with homogenous microstructure. TiC reinforcement varied from 5 to 50 wt.% into nickel matrix to investigate its effect on the microstructure and mechanical behavior of Ni-TiC composites. All Ni-TiC composites powder was mechanically alloyed using planetary high energy ball mill with 400 rpm and ball to powder ratio (BPR) 15:1 for 24 h. Bulk Ni-TiC composites were then sintered via SPS process at 50 MPa pressure and 900–1200 °C temperature. All Ni-TiC composites exhibited higher microhardness and compressive strength than pure nickel due to the presence of homogeneously distributed TiC particles within the nickel matrix, matrix grain refinement, and excellent interfacial bonding between nickel and TiC reinforcement. There is an increase in Ni-TiC composites microhardness with an increase in TiC reinforcement from 5 to 50 wt.%, and it reaches the maximum value of 900 HV for Ni-50TiC composites.     

Comparative Study on Electrical Conductivity of CeO2-Doped AlN Ceramics Sintered by Hot-Pressing and Spark Plasma Sintering

Aluminum nitride (AlN) ceramics were prepared by both Hot-pressing (HP) and Spark-Plasma-Sintering (SPS) using cerium oxide as the sintering aid. The characterization of AlN raw powder denoted the presence of an amorphous layer that led to the formation of aluminum oxide. During the sintering process, CeO₂ introduced as a sintering aid was reduced into Ce₂O₃. The latter reacted with aluminum oxide to form a transient liquid phase that promotes sintering by both HP and SPS. A reactional path leading to the formation of secondary phases, such as CeAlO₃ and CeAl₁₁O₁₈, has been proposed according to the pseudo-binary Al₂O₃ – Ce₂O₃. Ceramics obtained from HP and SPS are presented as similar, except for the secondary-phase distribution. The influences of secondary phase composition and distribution on electrical conductivity were evaluated by leakage current measurements. The mechanism of DC conduction and the global conductivity of ceramics were discussed according to the sintering process and the number of secondary phases.     

Effect of Heating Modes on Reactive Sintering of Ca3Co4O9 Ceramics

The traditional solid-state reaction method was employed to synthesize bulk calcium cobaltite (Ca349/Ca₃Co₄O₉) ceramics via ball milling the precursor mixture. The samples were compacted using conventional sintering (CS) and spark plasma sintering (SPS) at 850, 900, and 950 °C. The X-ray diffraction (XRD) pattern indicates the presence of the Ca349 phase for samples sintered at 850 and 900 °C. In addition, SPS fosters higher densification (81.18%) than conventional sintering (50.76%) at elevated sintering temperatures. The thermo-gravimetric analysis (TGA) and differential thermal analysis (DTA) performed on the precursor mixture reported a weight loss of ~25.23% at a temperature range of 600–820 °C. This current work aims to analyze the electrical properties (Seebeck coefficient (s), electrical resistivity (ρ), and power factor) of sintered samples as a function of temperature (35–500 °C). It demonstrates that the change in sintering temperature (conventional sintering) did not evince any significant change in the Seebeck coefficient (113–142 μV/K). However, it reported a low resistivity of 153–132 μΩ-m and a better power factor (82–146.4 μW/mK²) at 900 °C. On the contrary, the SPS sintered samples recorded a higher Seebeck coefficient of 121–181 μV/K at 900 °C. Correspondingly, the samples sintered at 950 °C delineated a low resistivity of 145–158 μΩ-m and a better power factor (97–152 μW/mK²).     

Spark Plasma Sintering of Commercial Zirconium Carbide Powders: Densification Behavior and Mechanical Properties

Commercial zirconium carbide (ZrC) powder is consolidated by Spark Plasma Sintering (SPS). Processing temperatures range from 1650 to 2100 °C. Specimens with various density levels are obtained when performing single-die SPS at different temperatures. Besides the single-die tooling setup, a double-die tooling setup is employed to largely increase the actual applied pressure to achieve higher densification in a shorter processing time. In order to describe the densification mechanism of ZrC powder under SPS conditions, a power-law creep constitutive equation is utilized, whose coefficients are determined by the inverse regression of the obtained experimental data. The densification of the selected ZrC powder is shown to be likely associated with grain boundary sliding and dislocation glide controlled creep. Transverse rupture strength and microhardness of sintered specimens are measured to be up to 380 MPa and 24 GPa, respectively. Mechanical properties are correlated with specimens’ average grain size and relative density to elucidate the co-factor dependencies.     

Influence of Elemental Carbon (EC) Coating Covering nc-(Ti,Mo)C Particles on the Microstructure and Properties of Titanium Matrix Composites Prepared by Reactive Spark Plasma Sintering

This paper describes the microstructure and properties of titanium-based composites obtained as a result of a reactive spark plasma sintering of a mixture of titanium and nanostructured (Ti,Mo)C-type carbide in a carbon shell. Composites with different ceramic addition mass percentage (10 and 20 wt %) were produced. Effect of content of elemental carbon covering nc-(Ti,Mo)C reinforcing phase particles on the microstructure, mechanical, tribological, and corrosion properties of the titanium-based composites was investigated. The microstructural evolution, mechanical properties, and tribological behavior of the Ti + (Ti,Mo)C/C composites were evaluated using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), electron backscatter diffraction analysis (EBSD), X-ray photoelectron spectroscopy (XPS), 3D confocal laser scanning microscopy, nanoindentation, and ball-on-disk wear test. Moreover, corrosion resistance in a 3.5 wt % NaCl solution at RT were also investigated. It was found that the carbon content affected the tested properties. With the increase of carbon content from ca. 3 to 40 wt % in the (Ti,Mo)C/C reinforcing phase, an increase in the Young’s modulus, hardness, and fracture toughness of spark plasma sintered composites was observed. The results of abrasive and corrosive resistance tests were presented and compared with experimental data obtained for cp-Ti and Ti-6Al-4V alloy without the reinforcing phase. Moreover, it was found that an increase in the percentage of carbon increased the resistance to abrasive wear and to electrochemical corrosion of composites, measured by the relatively lower values of the friction coefficient and volume of wear and higher values of resistance polarization. This resistance results from the fact that a stable of TiO₂ layer doped with MoO₃ is formed on the surface of the composites. The results of experimental studies on the composites were compared with those obtained for cp-Ti and Ti-6Al-4V alloy without the reinforcing phase.     

From Powders to Dense Metal Parts: Characterization of a Commercial AlSiMg Alloy Processed through Direct Metal Laser Sintering

In this paper, a characterization of an AlSiMg alloy processed by direct metal laser sintering (DMLS) is presented, from the analysis of the starting powders, in terms of size, morphology and chemical composition, through to the evaluation of mechanical and microstructural properties of specimens built along different orientations parallel and perpendicular to the powder deposition plane. With respect to a similar aluminum alloy as-fabricated, a higher yield strength of about 40% due to the very fine microstructure, closely related to the mechanisms involved in this additive process is observed.     

The ZnO-In2O3 Oxide System as a Material for Low-Temperature Deposition of Transparent Electrodes

The development of optoelectronic devices based on flexible organic substrates substantially decreases the possible process temperatures during all stages of device manufacturing. This makes it urgent to search for new transparent conducting oxide (TCO) materials, cheaper than traditional indium-tin oxide (ITO), for the low-temperature deposition of transparent electrodes, a necessary component of most optoelectronic devices. The article presents the results of a vertically integrated study aimed at the low-temperature production of TCO thin films based on a zinc-indium oxide (ZIO) system with acceptable functional characteristics. First, dense and conducting ceramic targets based on the (100-x) mol% (ZnO) + x mol% (In₂O₃) system (x = 0.5, 1.5, 2.5, 5.0, and 10.0) were synthesized by the spark plasma sintering method. The dependences of the microstructure and phase composition of the ZIO ceramic targets on the In₂O₃ content have been studied by powder X-ray diffraction, scanning electron microscopy and energy dispersive X-ray spectroscopy methods. Then, a set of ZIO thin films with different Zn/In ratios were obtained on unheated glass substrates by direct current (dc) magnetron sputtering of the sintered targets. Complex studies of microstructure, electrical and optical properties of the deposited films have revealed the presence of an optimal doping level (5 mol% In₂O₃) of the ZIO target at which the deposited TCO films, in terms of the combination of their electrical and optical properties, become comparable to the widely used expensive ITO.