Pulse Electric Current Synthesis and Processing of Materials

305 Pages·2006·8.305 MB·English

Pulse Electric
Current Synthesis and
Processing of Materials
Pulse Electric
Current Synthesis and
Processing of Materials
Proceedings of the 6th Pacific Rim
Conference on Ceramics and Glass Technology
(PacRim6), September 11-16, Maui, Hawaii
Editors
Zuhair A. Munir
Manshi Ohyanagi
Masao Tokita
Michael Khor
Toshio Hirai
Umberto Anselmi-Tamburini
VX/INTERSCIENCE
A JOHN WILEY & SONS, INC., PUBLICATION
Copyright © 2006 by the American Ceramics Society. All rights reserved.
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Library of Congress Cataloging-in-Publication Data is available.
ISBN-13 978-0-470-08156-3
ISBN-10 0-470-08156-2
Printed in the United States of America.
10 9 8 7 6 5 4 3 21
Contents
Preface ix
The SPS Process: Characterization and Fundamental Investigations
Study on the Process Mechanism in Spark Plasma Sintering 3
Zhengyi Fu, Kun Wang, Tianya Tan, Yan Xiong, Daihua He, Yucheng Wang,
and Zuhair A. Munir
The Spark-Plasma-Sintering (SPS) Process in Comparison With 23
Various Conventional Compaction Methods
Paul Angerer, Erich Neubauer, Li Gen Yu, and Khiam Aik Khor
Fundamental Investigations of Reactivity and Densification in 37
the SPS
U. Anselmi-Tamburini and Z. A. Munir
Development of Advanced Spark Plasma Sintering (SPS) Systems 51
and Its Industrial Applications
Masao Tokita
Calculation of Electric Field and Spark of Punch Surface For Pulsed 61
Electric Current Sintering
D. M. Zhang, L. M. Zhang, and Z. Z. Wang
Sintering Studies by Pulsed Electric Current
Preparation of Porous Alumina Ceramics by Spark Plasma Sintering 73
Won-Seung Cho, Yeon-Chul Yoo, Chin Myung Whang, Nam-Hee Cho,
Jun-Gyu Kim, Young-Jae Kwon, and Z. A. Munir
Ti/Hydroxyapatite Hybrid Material Prepared by Spark 83
Plasma Sintering
T. Tsujimoto, T. Tanaka, K. Oshiro, H. Fujimori, M. Matsuura, S. Goto, and
S. Yamamoto
v
Sintering Behavior of Aluminum Alloy-Carbon Composite by SPS 89
Takashi Yoshioka, Kiminori Sato, Shinsuke Tanaka, Sumasu Yamada, and
Yukio Makino
Spark Plasma Sintering of Less-Crystallized Boron Carbide 101
with Defects
Yasuhiro Kodera, Naoaki Isibashi, Takahito Imai, Takeshi Yamamoto,
Manshi Ohyanagi, Umberto Anselmi-Tamburini, and Zuhair A. Munir
High-Density (Na, K)Nb0 Piezoelectric Ceramics Fabricated by 113
3
Spark Plasma Sintering
T. Saito, T. Ochiai, Y. Matsuo, and T. Wada
Preparation of Amorphous Sintered Body 125
Kazuyuki Kakegawa, Naoki Akiyama, Sofia Saori Suzuki, Naofumi Uekawa, and
Takashi Kojima
SiCp/AI Composites Fabricated by Spark Plasma Sintering 133
L M. Zhang, X. F. Gu, D. M. Zhang, M. J. Yang, and Z. Z. Wang
Structural Transformation of Stacking Disorder SiC with Densification 143
by Spark Plasma Sintering
Yasuhiro Kodera, Naoki Toyofuku, Takeshi Yamamoto, Manshi Ohyanagi, and
Zuhair A. Munir
Consolidation of Carbon Material with Disordered Structure by 153
Spark Plasma Sintering
Takeshi A. Yamamoto, Takayuki Nakayama, Manshi Ohyanagi, Atsuki Kaneuchi,
and Zuhair A. Munir
Spark Sintering Rate of Pure Copper Powder Compact 161
K. Matsugi, H. Kuramoto, G. Sasaki, and O. Yanagisawa
Synthesis/Sintering of Dense Carbides-, Borides- and Perovskites- 173
Based Materials by SPS
Antonio Mario Locci, Roberta Licheri, Roberto Orru, Alberto Cincotti, and
Giacomo Cao
Simultaneous Synthesis and Densification of TiSi /SiC Submicron- 189
2
Composites via Spark Plasma Sintering
Lianjun Wang, Wan Jiang, Chao Qin, and Lidong Chen
Consolidation of Nanostructured Materials
Spark Sintering of Electroless Nickel or Tin Plated Metal, Carbide 197
Oxide and Sulfide Powders
K. Matsugi, G. Sasaki, and O. Yanagisawa
vi • Pulse Electric Current Synthesis and Processing of Materials
Synthesis and Consolidation of Zirconia Nanopowders via a Unique 209
Reverse Micelle Synthesis Process and Spark Plasma Sintering
Olivia A. Graeve, Harpreet Singh, and Andrew Clifton
Consolidation of Nano-Ceramics by SPS; Kinetic Considerations 225
Mats Nygren and Zhijian Shen
Production of Dense Nanostructured Materials Using FAPAS and 235
SPS Techniques
Frederic Bernard, Eric Gaffet, and Zuhair Munir
Pore Free Consolidation with Nanocrystalline Control in Ceramics 251
Hiroshi Kimura
Property Evaluation of Pulse Electric Current Sintered Materials
Mechanical Properties of Hydroxyapatites Sintered by Spark 265
Plasma Sintering
Takumi Nakamura, Tatsuya Fukuhara, and Hiroshi Izui
Evaluation of Al-Si-C-N Ceramics Fabricated by Spark Plasma 273
Sintering
Ryota Kobayashi, Junichi Tatami, Toru Wakihara, Katsutoshi Komeya,
Takeshi Meguro, and Takashi Goto
Thermoelectric Properties of P-Type Bio^Sb-, Te Compounds 279
5 3
Prepared by Spark Plasma Sintering Method
D. C. Cho, S. Y. Kim, C. H. Lim, W. S. Cho, C. H. Lee, S. Y. Shin, and Z. A. Munir
Mechanical Properties of Ti-15-3 Alloy Reinforced With SiC Fibers 289
by Spark Plasma Sintering
Hiroshi Izui, So Kinbara, and Michiharu Okano
Crystallographic Behaviors of Nano-Powder Anatase Consolidated 301
by SPS Method
Yukio Makino
Index 313
Pulse Electric Current Synthesis and Processing of Materials • vii
Preface
Sintering as an art had origins that are thousands of years old. The formation of
bricks by heating clay bodies in an open pit fire is one of the earliest examples of
sintering practiced by ancient civilizations of Mesopotamia. The practice is known
to have existed as far back as 6000 BC. Understanding the basic phenomena and
the important parameters governing sintering has led to investigation on means to
activate the process. The objective of these investigations was to enhance mass
transport to either make possible the sintering of extremely refractory materials or
to lower the temperature of consolidation. One of the methods of activating the
sintering process involves the use of electrical current. Although the recent wide-
spread use of this approach has been generated by the availability of commercial-
ly built devices, its origin is much older. Patents issued as early as 1933 describe
methods in which an electric discharge or current is utilized to aid in the sintering
of powders or the sinter-joining of metals. The use of a current to aid in the sin-
tering of materials has been applied in a large number of investigations.
Commercial units, which have been developed over the past few decades, include
"plasma-activated sintering" (PAS), "pulsed electric current sintering" (PECS),
"electroconsolidation" also known as electric pulse assisted consolidation (EPAC),
and "spark plasma sintering" (SPS). Although the generic name pulse electric cur-
rent sintering (PECS) is gaining popularity, most published papers use the term
SPS to refer to the method.
The emerging theme from the large majority of investigations of current acti-
vated sintering is that it has decided advantages over conventional methods in-
cluding pressureless sintering, hot-pressing, and others. These advantages include:
lower sintering temperature, shorter holding time, and marked comparative im-
provements in properties of materials consolidated by this method. Lower temper-
atures and shorter holding times have made it possible to sinter nanometric pow-
ders to near theoretical values with little grain growth. While in most cases the
evidence demonstrating the superiority of the current activated sintering is clearly
presented, the explanations given to rationalize these advantages fall short of sci-
entific adequacy.
IX
The importance of the SPS method as a tool for consolidation of powders
process is demonstrated by the large number of papers published during the past
decade. There has been a seemingly exponential increase in the number of papers
published since 1994. In that year only a handful of papers were published while in
the last year with complete data (2003), more than 150 papers were published.
Since the effort to commercialize the method was initiated in large scale in Japan, it
is not surprising that the vas majority of papers published are from Japan. China and
Korea are second and third, respectively, while the other countries contributed few-
er than about 30 papers each. In part this distribution reflects the availability of the
equipment in these countries, with Japan having by far the largest number of SPS
units.
In view of the above, it is not surprising that four symposia on the topic of SPS
have been organized in the past. The fifth and most recent symposium was orga-
nized to be part of the 6th Pacific Rim Conference on Ceramic and Glass Technolo-
gy (PAC RIM 6), which was held September 11-16, 2005 in Maui, Hawaii. The
proceedings of the Fifth International Symposium on Spark Plasma Synthesis and
Processing (ISSPSP-5) are printed in this volume of Ceramic Transactions. This
represents the first effort to publish the Proceedings in a widely distributed publica-
tion forum.
In organizing the symposium we have planned sessions on the following topics:
• The SPS Process: Characterization and Fundamental Investigations
• Sintering Studies by Pulsed Electric Current
• Consolidation of Nanostructured Materials
• Property Evaluation of Pulse Electric Current Sintered Materials
This proceedings is organized to reflect these topics. We are hopeful that the col-
lection of these papers, representing the most recent work on the SPS process, will
provide an important source of information to scientists in the worldwide communi-
ty of synthesis and processing of materials. The papers in this volume present both
fundamental and applied work. In the former, many attempts have been made to
provide a fundamental understanding to the SPS process, and in the latter investiga-
tions have been made demonstrating success in synthesizing or consolidating mate-
rials possessing unusual or highly improved properties.
We are grateful to the assistance provided to us by several individuals. We
thank Dr. Sylvia M. Johnson, the General Chair of PacRim 6 for her support. We
are indebted to the meetings and technical publications staff at The American
Ceramic Society for their help with the review process of the submitted papers.
Without their help this Ceramic Transactions volume would not have been possi-
ble.
Finally, we express our gratitude to the organizations that provided financial
support to provide travel assistance to invited speakers. We are grateful to: The
National Science Foundation (Dr. Linda Blevins, Program Director); The U.S.
Army Research Office, ARO (Dr. William Mullins, Program Director); Sumitomo
x • Pulse Electric Current Synthesis and Processing of Materials
Coal Mining Company, Ltd. (Currently: SPS Syntex, Inc.); SCM Systems, Inc.;
Suga Company Ltd.; and Bits Corporation (Mr. Yoshio Kanno, President).
Zuhair A. Munir, University of California, Davis, USA
Manshi Ohyanagi, Ryukoku University, Japan
Masao Tokita, SPS Syntex, Inc., Japan
Michael Khor, Nanyang Technological University, Singapore
Toshio Hirai, Japan Fine Ceramics Center, Japan
Umberto Anselmi-Tamburini, University of Pavia, Italy
Pulse Electric Current Synthesis and Processing of Materials • xi
Pulse Electric Current Synthesis and Processing of Materials
Edited by Zuhair A. Munir, Manshi Ohyanagi, Masao Tokita,
Michael Khor, Toshio Hirai and Umberto Anselmi-Tamburini
Copyright © 2006 The American Ceramics Society
The SPS Process:
Characterization and
Fundamental Investigations