Abstract
Control of the sintering defects in metal/ceramic functionally graded materials was examined with the aide of numerical analysis. Warping, cracking and delamination were observed in the sintered bodies of laminated powder mixtures of stainless steel and alumina used as a model system. The causes of the sintering defects were related to the lack of sintering balance of the layers. To improve the sintering balance, larger particles were used for some layers and warping and delamination were suppressed while cracking was not. Sintering behavior of each layer was expressed by a constitutive model for sintering and the deformation of the laminated powder compacts during sintering was analyzed by the finite element method. The analytical results showed warping of the compacts and revealed the internal stress in the layer where cracking occurred. The suppression of warping was also predicted in the analysis and the usefulness of the analysis for the design of functionally graded materials was confirmed.
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