The plasma sintering method, also known as Spark Plasma Sintering (SPS), is a sintering technique that uses pressure and an electric field to enhance the density of ceramic and metallic powder compacts.
This method allows for lower sintering temperatures and less time compared to conventional sintering techniques.
The process involves four main stages: gas removal and vacuum, application of pressure, resistance heating, and cooling.
The high sintering rate in SPS is due to internal heating of the sample, which is achieved through the use of pulsed DC to generate local high temperatures and plasma discharges between particles.
This results in the melting and bonding of particles, leading to the formation of a dense sintered body.
What is the Plasma Sintering Method? 4 Key Stages Explained
1. Process Stages
Gas Removal and Vacuum
This initial stage ensures that the environment is free from gases that could affect the sintering process or the final product's quality.
Application of Pressure
Pressure is applied to the powder compact to facilitate the sintering process and enhance the density of the final product.
Resistance Heating
This stage involves the use of pulsed DC to generate heat within the sample.
The electrical discharge between powder particles results in localized and momentary heating of the particles' surfaces, which can reach several thousands of degrees Celsius.
This heating is uniformly distributed throughout the sample volume, purifying and activating the particle surfaces by vaporizing impurities.
Cooling
After the particles have melted and bonded, the sample is cooled to solidify the sintered body.
2. Advantages of SPS
High Sintering Rate
SPS can complete the sintering process in a few minutes, compared to hours or days required by conventional sintering.
This is due to the internal heating mechanism, which allows for high heating rates.
Control of Grain Size
The high sintering energy and localized heating prevent grain growth within the particles, allowing for effective control of the grain size in the sintered body.
Versatility
SPS can be applied to a variety of materials, including ceramics, composites, and nanostructures, unlike other sintering processes that are limited to metal processing.
3. Misconceptions and Alternative Names
The term "Spark Plasma Sintering" is somewhat misleading as it does not actually involve plasma.
As a result, alternative names such as Field Assisted Sintering Technique (FAST), Electric Field Assisted Sintering (EFAS), and Direct Current Sintering (DCS) have been proposed to more accurately describe the process.
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