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two stage
sintering
1750C
1450C-20h
Scripta Mater. 54 (2006) 615.
Al2O3-5% Ni nanocomposite (reductionpressureless sintered @ 1773K)
Simultaneous application of
preessssuurre aannddhheat
Pressure
Temperature
SiC Nanoceramics
~ 40 nm T2
(C)
20oC/min
40oC/min
Time (hr)
J.Am.Ceram.Soc. (2003).
Al2O3-SiC nano composite
Composite A 30 (1999)425
Toughened Alumina
In-situ crystallization of
Si3N4 and SiC led to formation
on Nano/Nano composite.
Enhanced superplasticity
was observed. [M. Yoshimura et al.; Scripta Mater. 44 (2001) 1517-1521]
Si3N4/BN nanocomposite
Appropriate selection of external stress and temperature necessary for the superplastic deformation
Longer sintering duration results in the grain coarsening.
SPS :
Simultaneous application
of pressure and heat-
similar tooHHPP
Dense Material
Sintering temperature
lower by 2003000C.
Initial activation of powders by pulsed
voltage.
Holding time 05 min.
Resistance sintering under pressure.
Total processing time:
20 min. Spark Plasma Sintering : a promising processing to
Commercial SPS
When spark discharge appears in the gap between the particles of a material, a
local high temperature state occurs. This causes vaporization and the melting of
the surfaces of the powder particles during the SPS process; constricted shapes
or necks are formed around the contact area between the particles. These
necks gradually develop and plastic transformation progresses during sintering,
resulting in a sintered compact of over 99% density. Since only the surface
temperature of the particles rises rapidly by selfheating, particle growth of the
starting powder materials is controlled.
Chapter 12 -
Pressure Pressure Pressure
Powder Particles(A)
Cathode
(IV) Generation of spark impact pressure, sputtering of (V) Enhanced neck growth in the presence of
vaporized/molten particles spark plasma
SPS process
The pulsed discharge achieved by the application of an on/off low voltage
(~ 30 V) and high current (> 600 A). The duration of each pulse varies
between 1 and 300 ms.
For SPS Process, electrical discharge by itself does not consolidate powders
and, therefore, some additional effects are needed to increase the final
density (pressure application and/or higher temperature than that created by
electrical discharge
SPS sintering temperatures range from low to over 2000oC, which are
typically ~ 200500oC lower than conventional sintering
Vaporization, melting and sintering completed in short periods of ~ 520
minutes, including temperature rise and holding times
Physics of SPS process
Formation of small capacitors at the contact between particles/at gap
around the contact.
Mechanical properties:
Hardness: 26.2 GPa (monolithic Al2O3
hardness ~ 19 GPa)
Toughness: 6.2 MPa m1/2
[G. D. Zhan et al.; J. Am. Ceram. Soc. 87[12]
(2004) 2297-2300]
Strength obtained by various Al2O3 based
nanocomposites
1200
conventional monolithic Al2O3
1100 Al2O3 - 5 vol% SiC nanocomposite[77]
Al2O3 - 5 vol% SiC nanocomposite[100]
Al2O3 - 15 vol% SiC nanocomposite[77]
1000
Al2O3 - 18 vol% SiC nanocomposite[103]
Al2O3 - 35 vol% TiC nanocomposite[106]
Strength (MPa)
900
800
700
600
500
400
0 5 10 15 20 25 30 35 40
vol% reinforcement
Zenith of strength obtained at 5 vol% reinforcement
Nanocomposites based on WC
Mechanical properties:
Superior hardness of ~ 24 GPa (Hardness of
conventional cermet: 14-16 GPa)
Moderate toughness of ~ 6-7 MPa m1/2
Densification of WCC--6 wwt. % ZrO2 : SPS route
100
98
Relative density (%)
96
94
92
20 4
Basu et al., J. Am. Cer. Soc., 87 [2] (2004) 317-319
Hardness
m1/2
Toughness
18 2
1150 1200 1250 1300 1350
SPS temperature, oC
WC
WC
SPS @ 13000C
Intensity (arbitrary)
WC
t-ZrO2
25 30 35 40 45 50 55
2 (degree)
No detectable reaction between WC and ZrO2 under SPS conditions
96
94
90
1100 1150 1200 1250 1300
Sintering temperature, 0C
Other processing routes:
4.5
3.0
m1/2
Hardness
Toughness
14.0 2.5
1250 1200 1300
SPS Temperature, oC
Hot Pressing at 14500C, 1h, vacuum: 13.3 GPa, 4.8 MPa m1/2
Pressureless sintering at 14500C, 2h, air: 11.7 GPa, 4.9 MPa m1/2
Microstructure: SPS - pprroocceesssseeddTZP
SPS at 13000C
t-ZrO2
Intensity (a.u)
25 26 27 28 29 30 31 32 33 34 35
2 (degrees)
Wear resistance of 3Y-TZP nanoceramics
Average grain sizes
80 nm 150 nm 200 nm 300 nm
Mechanical properties:
Hardness: 15.2 GPa
Toughness: 8.9 MPa m1/2 (Toughness of
monolithic Al2O3 ~ 3-4MPa m1/2)
[Scripta Materialia 47 (2002) 737-741]
Nanocomposites based on ZrO2/ZrB2
ZrO230vol%ZrB2 nanocomposite
processed via SPS at 12000C
(600 K/min)
Mechanical properties:
Hardness: ~ 14 GPa
Toughness: ~ 10 MPa m1/2
14.6 9.0
14.4 8.5
14.2 8.0
14.0
7.5
13.8
7.0
13.6
6.5
13.4
13.2 6.0
Hardness Toughness
13.0 5.5
2.0 2.2 2.4 2.6 2.8 3.0
Chapter 12 -
Overall Yttria Content (mol%)