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An energy efficient spark plasma sintering method enabling the densification of large size samples assisted by very low electric current levels is developed. In this method, the electric current is concentrated in the graphite foils around the sample. High energy dissipation is then achieved in this area enabling the heating and full densification of large (alumina) parts ({{O}} 40 mm) at relatively low currents (800 A). The electrothermal mechanical simulation reveals that the electric current needed to heat the large samples is 70 % lower in the energy efficient configuration compared to the traditional configuration. The presence of thermal and densification gradients is also revealed for the larger size samples. Potential solutions for this problem are discussed. The experiments confirm the possibility of full densification (96-99 %) of large alumina samples. This approach allows using small (and low cost) SPS devices (generally limited to 10-15 mm samples) for large size samples (40-50 mm). The developed technique enables also an optimized energy consumption by large scale SPS systems.
A new flash (ultra-rapid) spark plasma sintering method applicable to various materials systems, regardless of their electrical resistivity, is developed. A number of powders ranging from metals to electrically insulative ceramics have been successfu
This work addresses the two great challenges of the spark plasma sintering (SPS) process: the sintering of complex shapes and the simultaneous production of multiple parts. A new controllable interface method is employed to concurrently consolidate t
The 3 heating modes are utilized to make ZrN powders have 3 different levels of the electric current density at the same temperature during spark plasma sintering (SPS). The constitutive equation of sintering for SPS is applied to the experimental po
Graphite creep has high importance for applications using high pressures (100 MPa) and temperatures close to 2000 {textdegree}C. In particular, the new flash spark plasma sintering process (FSPS) is highly sensitive to graphite creep when applied to
The stability ofthe proportional--integral--derivative (PID)controlof temperature in the spark plasma sintering (SPS) process is investigated.ThePID regulationsof this process are tested fordifferent SPS toolingdimensions, physical parameters conditi