Abstract
Spark plasma sintering (SPS) has gained recognition in the last 20 years for its rapid densification of hard-to-sinter conventional and advanced materials, including metals, ceramics, polymers, and composites. Herein, we describe the unconventional usages of the SPS technique developed in the field. The potential of various new modifications in the SPS technique, from pressureless to the integration of a novel gas quenching system to extrusion, has led to SPS’ evolution into a completely new manufacturing tool. The SPS technique’s modifications have broadened its usability from merely a densification tool to the fabrication of complex-shaped components, advanced functional materials, functionally gradient materials, interconnected materials, and porous filter materials for real-life applications. The broader application achieved by modification of the SPS technique can provide an alternative to conventional powder metallurgy methods as a scalable manufacturing process. The future challenges and opportunities in this emerging research field have also been identified and presented.
Highlights
Spark plasma sintering (SPS) is an ultra-fast technique utilizing the electric field and pressure to consolidate and densify conventional and advanced materials
SPS processing enables the formation of a unique microstructure at the bonding layer, not seen in the joints obtained from conventional techniques [32,43,44]
This illustrates that current, electric fields, and pressure during SPS processing have dramatically enhanced the degree of freedom in materials’ design
Summary
Spark plasma sintering (SPS) is an ultra-fast technique utilizing the electric field and pressure to consolidate and densify conventional and advanced materials. The spark between the particles activates their surface, removes volatile impurities, surface oxide contaminations, and effectively self-heats the material. This localized effect enables the lower sintering temperature and shorter time and often leads to a dense finegrained structure with higher strength [9]. Various other mechanisms such as plasma or micro-discharge of the particles’ surface, Joule heating, electromigration, local melting, and evaporation have been reported for the conventional SPS technique. Future trends, perspectives, and opportunities in the research field have been identified
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