Sintering Process Research Articles

Development of a Low-carbon Sintering Process Technology and Its Application to a Pilot-scale Sintering Testing

Development of a Low-carbon Sintering Process Technology and Its Application to a Pilot-scale Sintering Testing

Cold Sintered ZnO-Polystyrene (PS) Composites with Modified Interfacial Structures and Properties.

Lightweight and integrated electronic devices with high performance have become an inevitable trend in the development of power electronic systems. However, it is challenging to obtain lightweight and miniaturized varistors due to the low threshold electric field. Herein, (1 - x)ZnO-xPS composites with a high threshold electric field are prepared through a cold sintering process at 220 °C for 50 min, utilizing lightweight PS to modulate the grain boundary structures of ZnO varistors. With PS content ≤1.5 wt %, the relative densities of cold sintered composites exceed 95%. PS thin layers with a thickness of 2-10 nm are distributed at the grain boundaries of ZnO, forming the Schottky barrier, which triggers nonlinear current-voltage responses. With the addition of PS, the threshold electric field is dramatically enhanced from 135 to 2703 V·mm-1, higher than that of commercial ZnO varistors, which is further demonstrated by the electric field simulation of the Finite Element Method. The interfacial resistance obtained from impedance analysis increases with the increase of the PS content, and the activation energy of (1 - x)ZnO-xPS composites is higher than that of pure ZnO ceramics. This study provides a promising approach for the development of lightweight and cost-effective varistor materials.

Cost Optimization in Sintering Process on the Basis of Bulk Queueing System with Diverse Services Modes and Vacation

This research investigated a single bulk server queuing model where service modes and server vacations are dependent on the number of clients. The server operates in three different service modes: single service, fixed batch service, and variable batch service. Modes will be determined by queue length. The service starts only when the minimum number of customers, say ‘a’, has accumulated in the queue. At this point, the server selects one of three service modes. Transitions between duty modes are permitted only at the beginning of a duty period. At the end of the service, the server can go on vacation if the queue length drops below ‘a’. When returning from vacation, if threshold ‘a’ is not reached, the server will remain inactive until it is reached. A special technique called the Supplementary Variables Technique (SVT) was used to determine the probability-generating function when estimating the queue size at a given time. Appropriate numerical examples exemplify the method developed in the paper. An optimal cost analysis was performed to set the threshold values for different server modes with the intention of minimizing the aggregate average cost.

Application of thermodynamic equilibrium modelling to predict slagging and fouling tendencies of bituminous coal and wheat straw blends

The combustion or co-combustion of biomass or alternative fuels is important in the energy sector because of the need to reduce the share of fossil fuels. This article is a continuation of previous studies on the behaviour of the mineral matter of selected fuels during the sintering processes. The blends of wheat straw biomass from Polish crops (WS) with bituminous coal from the Makoszowa mine (BC) were studied. The study included proximate and ultimate analysis and oxide analysis of ash blends with the following composition: 10wt% WS/90wt%BC, 25wt% WS/75wt%BC and 50wt% WS/50wt%BC. Based on the oxide content, a prediction (using FactSage 8.0 software) of the sintering process of the mixtures tested. The following parameters were determined: slag phase content, specific heat at constant pressure, and ash density. The fracture stresses tests were carried out using the mechanical test. Pressure tests were also performed using the pressure drop test method. The test results of all test methods used were compared with each other. On the basis of this comparison, a clear correlation was found between the sintering temperatures determined by the mechanical method and the pressure drop method and the physical properties of the ashes, such as density and heat capacity, as well as the chemical properties, i.e. the content of the slag phase. The results of the presented research are a valuable addition to the previous work of the authors. The goal of this work is to develop a precise and measurably simple method to determine the sintering temperature of ashes. This is an extremely important issue, especially in the case of the need to use a wide range of fuels in the energy industry.

Large internal stress induced nonlinear current-voltage behavior in nanodiamond strengthened ZnO ceramics.

The modulation of the electrostatic potential barrier at grain boundaries determines the performance of many ceramic-based electronics such as varistors. However, conventional protocols relying on complex doping and annealing processes inevitably increase the inhomogeneity of microstructure, which may jeopardize the performance stability and mechanical reliability in service. Instead of doping, herein we demonstrate an effective strategy to modulate the potential barrier in ZnO-based low-voltage varistors by exploiting internal stress-induced piezoelectric polarization. The local residual stress as large as ~1 GPa can be created in the ZnO matrix by incorporating ultra-stiff nanodiamond particles using a cold sintering process. As a result, the composite with only 2 wt% of nanodiamond exhibits a prominent nonlinear current-voltage response at a low switch voltage of 15.7 V/mm, which is ascribed to the depressed barrier height induced by the distinct effects of positively and negatively charged polarization on grain boundaries. More strikingly, the large internal stress can significantly enhance the strength of the composite by more than 230% compared with the monolith, owing to the highly strengthened grain boundaries and crack-tip bridging from prestressed nanodiamonds. These findings add internal stress as a new dimension to design mechanically robust ceramic electronics with high performance.

Boosting thermoelectric efficiency of Ag2Se through cold sintering process with Ag nano-precipitate formation

Boosting thermoelectric efficiency of Ag2Se through cold sintering process with Ag nano-precipitate formation

Development of a Diamond Composite in the NI-CO-FE3P-SN-WC System Via Free Sintering for Use in Multi-Find Diamond Pearls

Objective: The main objective of this study is to manufacture a diamond composite with a metallic matrix based on Ni-Co-Fe3P-Sn-WC, using the Free Sintering process through cold uniaxial compaction, intended for the production of pearls for diamond wire saws, used in cutting ornamental stones. Theoretical Framework: The multi-wire technology represents an advancement in cutting ornamental stone blocks, allowing the simultaneous production of multiple slabs. Powder metallurgy is the predominant technique used in the manufacturing of pearls for diamond wire saws. Through testing, including scanning electron microscopy (SEM) and shear tests, it is possible to evaluate the alloy's strength, diamond crystal adhesion, and failure behavior of the alloy. Methodology: The adopted methodology involves the processing and characterization of pearls for diamond wire saws, following the techniques of powder metallurgy. Initially, parametric calculations were performed using Excel, providing a basis for subsequent analyses. Diamond-coated pearls were produced with different proportions of constituent elements, and uniaxial compressive strength tests and microstructural characterization were conducted to evaluate the results. Results and Discussion: In the adhesion tests to the metal tube, the pearls produced with the NICOFE alloy showed similar performance to the commercial pearls "A" and "B," with satisfactory direct shear strength values. However, some point defects were observed, such as porosity in the transition zone, creating a weaker bond, negatively impacting the final strength of the composite. Analysis of the commercial samples indicated that diamond abrasion was not related to the composition of the sintered alloy. Research Implications: This research suggests significant economic and technological implications, such as the development and nationalization of technology for the ornamental stone industry. The use of the NICOFE alloy could strengthen the local industry by providing a viable and more accessible alternative for the production of diamond pearls. Originality/Value: The NICOFE blend presents technical advantages for manufacturing diamond wire pearls, highlighting the environmental benefits from reduced cobalt use and economic advantages by offering more accessible materials for the ornamental stone industry.

Impact of low-grade iron ore on sintering reactions: Rapid heating experiments and thermodynamic modeling

BackgroundSinter is a primary feedstock for blast furnace-based ironmaking. Recently, the proportion of low-grade iron ore, which contains a high amount of gangue (mainly SiO2), has been increasing in the sintering process. Therefore, the impact of increased SiO2 content on the quality of sinter needs to be clarified. MethodsIn this study, we designed a rapid-heating furnace to simulate the actual thermal profile of the sintering process. The effects of basicity values, sintering temperature, and atmosphere, on the microstructure and phase formation of the Fe2O3-CaO-SiO2 ternary mixtures during sintering reactions, are investigated using X-ray diffractometry and scanning electron microscopy. The experimental results are analyzed using CALPHAD-type computational thermodynamics. Significant findingsWe found that solid-state reactions dominate at the lower temperature of 1250 °C, while liquid-assisted sintering occurs at the higher temperature (1300 °C). As the SiO2 content in the sinter increases, the content of the calcium-ferrite bonding phase decreases, while the content of Ca2SiO4 and Fe2O3 increases. Regarding the role of the atmosphere, more calcium ferrite bonding phases form under a lower oxygen partial pressure compared to an ambient atmosphere, which facilitates the densification of the Fe2O3-CaO-SiO2 sinter. In addition, a guideline for sintering operation with low-grade iron ore is proposed.

In-Situ Constructing N,S-Codoped Carbon Heterointerface for High-Rate Cathode of Sodium-Ion Batteries.

Na3V2(PO4)3 (NVP) is considered one of the promising choices for cathodes of sodium-ion batteries, but the poor conductivity resulted inferior rate performance limited the practical development of NVP cathodes. In this study, we successfully synthesized N/S dual-atom doped carbon coatings in situ through a simple one-step solid-state sintering method. The uniformly coated carbon layer can inhibit the agglomeration and growth of active materials during the sintering process, shorten the Na+ migration path, and increase the contact area with the electrolyte, thus facilitating rapid Na+ migration. Notably, the doping of N elements can alter the electron distribution of carbon coating, enhancing electron conductivity. Furthermore, the introduction of S elements in the carbon layer can induce the formation of stable C-S-C bonds in the molecular layer, expanding the interlayer spacing, which is beneficial for Na+ transport and storage. Therefore, the modified NVP@NSC composite provides a high specific capacity of 90.3 mAh g-1 at a rate of 20 C, with a capacity retention rate of 94.4% after 8000 cycles, demonstrating excellent stability at high current densities. Moreover, the full cell exhibits remarkable electrochemical performance at 5 C. This research contributes to the practical development of NVP cathodes.

Intelligent Optimization and Impact Analysis of Energy Efficiency and Carbon Reduction in the High-Temperature Sintered Ore Production Process

The coordinated optimization of energy conservation, efficiency improvement, and pollution reduction in the sintering production process is vital for the efficient and sustainable development of the sintering department. However, previous studies have shown shortcomings in the multi-objective collaborative optimization of sintering systems and the quantification of pollutant impacts. To address these, this paper proposes a multi-objective optimization method integrated with the NSGA-III algorithm and establishes an integrated system optimization model for sintered ore production and high-temperature waste heat recovery. The results demonstrate significant improvements: energy utilization efficiency increased by 0.67%, energy consumption decreased by 17.3 MJ/t, production costs were reduced by 11.45 CNY/t, and the emissions of CO2, SO2, and NOx were reduced by 0.464 kg/t, 0.034 kg/t, and 0.008 kg/t, respectively. Additionally, the study identified optimal configuration parameters and analyzed the quantitative impact of several key factors on multiple indicators. The results also show that reducing the water content of the mixture, decreasing the middling coal content in the fuel, and increasing the thickness of the material layer are effective strategies to reduce energy consumption and pollutant emissions in the sintering process. Overall, implementing these optimizations can bring significant economic and environmental benefits to the steel industry.

Surface Self-Diffusion Induced Sintering of Nanoparticles.

Despite the critical role of sintering phenomena in constraining the long-term durability of nanosized particles, a clear understanding of nanoparticle sintering has remained elusive due to the challenges in atomically tracking the neck initiation and discerning different mechanisms. Through the integration of in situ transmission electron microscopy and atomistic modeling, this study uncovers the atomic dynamics governing the neck initiation of Pt-Fe nanoparticles via a surface self-diffusion process, allowing for coalescence without significant particle movement. Real-time imaging reveals that thermally activated surface morphology changes in individual nanoparticles induce significant surface self-diffusion. The kinetic entrapment of self-diffusing atoms in the gaps between closely spaced nanoparticles leads to the nucleation and growth of atomic layers for neck formation. This surface self-diffusion-driven sintering process is activated at a relatively lower temperature compared to the classic Ostwald ripening and particle migration and coalescence processes. The fundamental insights have practical implications for manipulating the morphology, size distribution, and stability of nanostructures by leveraging surface self-diffusion processes.

Vitrified metal composite bond for diamond grinding tools used for silicon carbide wafer thinning

The refractoriness of the vitrified bond significantly influences the properties of the vitrified metal-composite bond. In this study, we examined the effects of refractoriness and number of vitrified bonds incorporated into vitrified metal composite bonds in diamond abrasive tools. Furthermore, the effects of vitrified metal composite bonds on the microstructure, mechanical properties, and sintering process were systematically evaluated. Techniques, such as X-ray diffraction (XRD), thermogravimetry-differential thermal analysis (TG-DTA), scanning electron microscopy (SEM), and white light interferometry (WLI) were employed to analyze the phase composition of the vitrified metal composite bond, changes during the hot-pressing sintering process, microstructural morphology, and friction and wear behavior of the diamond abrasive composite bond. The flexural and impact strengths of the composite bond decreased with an increase in the refractoriness of the vitrified bond and number of bonds introduced. In particular, as the refractoriness of the vitrified bonds increased, their fluidity decreased. Finally, the hardness of the vitrified metal composite bond containing 3% vitrified bond (4#) reached 66.34–69.2 HRB, the porosity was 22.08%, and the surface roughness of the workpiece was 0.06 μm.

Effects of Sn addition in W-doped Ag paste against electrochemical corrosion and sulfurization

Purpose This study aims to address these challenges by enhancing the resistance of Ag-based pastes to corrosion and sulfurization, thereby improving their performance and weatherability in high-power and high-frequency electronic applications. Design/methodology/approach This study investigates the influence of Sn doping in W-doped Ag paste to enhance resistance against electrochemical corrosion and sulfurization. A systematic examination was conducted using transient liquid phase sintering and solid–liquid inter-diffusion techniques to understand the microstructural and electrochemical properties. Findings This study found that Sn addition in W-doped Ag paste significantly improves its resistance to electrochemical corrosion and sulfurization. The sintering process at 600°C led to the formation of an Ag2WO4 phase at the grain boundaries, which, along with the presence of Sn, effectively inhibited the growth of Ag2WO4 grains. The 0.5% Sn-doped samples exhibited optimal anti-corrosion properties, demonstrating a longer grain boundary length and a passivation effect that significantly reduced the corrosion rate. No Ag2S phase was detected in the weatherability tests, confirming the enhanced durability of the doped samples. Originality/value The findings of this study highlight the potential of Sn-doped Ag-W composites as a promising material for electronic components, particularly in environments prone to sulfurization and corrosion. By improving the anti-corrosion properties and reducing the grain size, this study offers a new approach to extending the lifespan and reliability of electronic devices, making a significant contribution to the development of advanced materials for high-power and high-frequency applications.

KH571 construct interfacial molecular bridge in calcium silicate/TMPTA/HDDA scaffolds for improving mechanical properties, biodegradability and photopolymerization

Digital Light Processing (DLP) offers the potential for personalized bone implants. Within this method, the interfacial bonding capacity of inorganic/organic materials and the solid-phase content of the slurry emerge as primary factors influencing scaffolds mechanical properties. In this research, KH571 was applied to establish an interfacial “molecular bridge”, adopting in situ coupling technology to forge stable covalent bonds between calcium silicate (CSi) and KH571. Chemical grafting, surface photografting, and photopolymerization techniques were then utilized to construct a photo-crosslinked network by CSi-KH571-TMPTA/HDDA slurry, thereby transforming the weak physical connections at the interface into strong chemical bonds. Consequently, the curing capacity and mechanical properties of the scaffolds were enhanced. Further control grain size, crystal phase transition, and shrinkage of CSi-KH571 scaffolds, post-treatment sintering processes were employed, resulting in scaffolds with a high content of β-CSi. Moreover, the optimal process parameters were selected concerning grafting rate, chemical composition, microscopic morphology, crystalline transformation, dimensional accuracy, mechanical properties, biodegradability and biocompatibility of CSi-KH571. The elastic modulus and compressive properties of CSi25-55 scaffolds exhibited a notable improvement of 29.71 % and 59.30 %, respectively, compared to CSi-50 scaffolds. By regulating the phase composition of CSi, CSi25-55 scaffolds were designed to possess a controllable degradation. In vitro cell culture experiments validated its excellent biocompatibility and promoted the proliferation and differentiation of bone marrow mesenchymal stem cells (BMSCs) as well as the deposition of bone matrix. Herein, a novel and sustainable approach has been promoted for enhancing the interfacial bonding capacity of inorganic/organic materials and the solid-phase content of printing slurry, which lays the foundation for the printing of high-resolution degradable bioceramic scaffolds.

Cu/AlN composite and functionally graded materials with high strength and high electrical- and thermal-conductivity fabricated by spark plasma sintering

In this study, Cu/AlN composites and functionally graded materials (FGMs) were fabricated with the spark plasma sintering method. It was observed that a two-step sintering process, involving sintering under low pressure as the initial stage to remove adsorbed chemicals on the powder, was an effective method for producing sintering objects with high relative density. The hardness of the composites significantly increased with higher volume fraction of aluminum nitride (AlN) particles, while electrical- and thermal-conductivity decreased. Nevertheless, the advanse impact of AlN on thermal-conductivity was found to be minimal. Additionally during compression test, a crack was noted at the interface between Cu and Cu-5 vol%AlN region in two-layered FGMs after, whereas no such crack was observed in the three-layered FGMs. Therefore, it is confirmed that the concept of FGMs is useful in overcoming the shortcomings of mutually exclusiveness among high strength, high electrical- and high thermal-conductively.

High ionic conductive Sodium β-alumina (SBA) and SBA-NaPF6 composite solid electrolytes prepared by cold sintering process

Sodium β-alumina (SBA) electrolytes are among the most excellent candidates for all-solid-state batteries due to their high electrochemical performances and low cost of sodium resources. However, thermally sintering at above 1400 °C is required to fabricate high dense SBA electrolytes, thus giving rise to a huge energy consumption. Here, dense SBA electrolytes and (1-x)SBA-xNaPF6 (x=5, 10, 15, 20 wt%) composites were fabricated using cold sintering process (CSP) below 300 °C with 2 mol/L NaOH solution as transient chemistry. The ionic conductivity of SBA electrolytes is significantly enhanced from 5.53×10-6 S·cm-1 to 5.91 × 10−4 S·cm−1 as 15 wt% NaPF6 was introduced to the composite, which is comparable with the SBA sintered above 1400 °C. CSP may provide a promising approach for the fabrication of solid-state electrolytes by avoiding the detrimental impact of high temperature heat treatment.

Effect of sintering process on microstructure and mechanical properties of spark plasma sintered TiB2-SiC-Si3N4 cermets

Effect of sintering process on microstructure and mechanical properties of spark plasma sintered TiB2-SiC-Si3N4 cermets

3D-printed laponite bioceramic triply periodic minimal surface scaffolds with excellent bioactivity for bone regeneration

Laponite (LAP) is a promising biomaterial for bone regeneration due to its reliable biocompatibility and excellent osteoinductivity in bone tissue engineering. However, the personalized manufacture of LAP bioceramic scaffolds with controlled complex architecture and high porosity remains challenging. This study used vat photopolymerization (VPP) to manufacture LAP bioceramic scaffolds with high precision and biological activity. We first selected a 40 wt% LAP bioceramic slurry for subsequent VPP printing based on stability experiments and viscosity characterization results. The curing parameters of the photosensitive bioceramic slurry and the degassing sintering process were studied to ensure the quality of the ceramic green bodies. Then, we characterized the effects of different sintering temperatures (1150°C, 1200°C, 1250°C) on the crystalline phase composition, microstructure, and mechanical properties of the LAP bioceramic. The research showed that the densification and compressive strength of the LAP bioceramic sintered at 1250°C reached 2.51 g/cm3 and 15 Mpa, respectively. Finally, the bioceramic scaffolds with different sintering temperatures were co-cultured with rat bone marrow mesenchymal stem cells to detect biocompatibility. The results showed that the three groups of scaffolds enhanced cell proliferation, adhesion, and osteogenic capacity. In conclusion, the LAP bone scaffolds by VPP presented the potential for bone repair.

Direct Ink Writing and Rapid Microwave Sintering of Alumina

The additive manufacturing of ceramics is gaining attention due to difficulties in fabricating complex ceramic parts because of its hard and brittle nature. Direct ink writing (DIW) is a unique process in which solid-loaded slurry is extruded to print complex-shaped ceramic parts directly. In the present work, a new composition of high-solid loaded (76 wt.%) alumina ink is prepared for printing ceramic parts with complex structures. The rheology of ink is optimized to ensure the shear thinning behavior of the ink, while thermogravimetric analysis (TGA) of the printed part was carried out to optimize the debinding temperature. The printed alumina part is sintered using the conventional furnace and rapid microwave sintering process, and a comparison has been made. Microwave, a rapid sintering method with a high heating rate, produced >97% dense specimen, while the hardness and flexural strength values of 15.18 ± 0.6 GPa and 148.87 ± 2.14 MPa were achieved, respectively. Rapid microwave sintering of additively manufactured ceramic parts can reduce the energy consumption and overall production time needed to manufacture ceramic parts.

Additive manufacturing of high-performance SiO2-Al2O3-K2O (Na2O) ceramic components via binder jetting technology

To resolve issues such as high sintering temperatures and relatively low relative densities and bending strengths of sintered bodies during the preparation of ceramic parts using binder jetting (BJ) additive manufacturing (AM) technology. In this study, high-performance SiO2-Al2O3-K2O (Na2O) ceramics were fabricated using quartz, kaolin, potassium feldspar, and sodium feldspar as raw materials through BJ technology. Initially, the sintering process of the BJ ceramics was studied by adjusting the ratio of potassium feldspar to sodium feldspar and the sintering temperature, which enhanced the relative density and bending strength of the silicate ceramics. Subsequently, using response surface methodology (RSM), the effects of print layer thickness (A), scraper speed (B), and ink volume per unit area (C) on the performance of the ceramics after sintering were investigated. Results indicated that the optimal parameters of the BJ printing process were determined using RSM: A was 250 μm, B was 3.44 mg cm−3, and C was 35 mm s−1. Under these conditions, the sintered ceramics achieved optimal relative densities, closed porosities, and flexural strengths of 89.05 %, 10.85 %, and 69.19 MPa for relative density, closed porosity, and flexural strength, respectively.