Improved Functionality of the Spark Plasma Sintering (SPS) - Technology
HELLDAHL L. 1, MIHIRETIE B. 1, SUZUKI S. 2
1 Kagaku Analys AB, Goteborg, Sweden; 2 Suga Co. Ltd, Hakodate, Japan
Research and development within the fields of metals and ceramics (in a very wide context) have during the last 30 years utilised SPS to densify materials: this as regards both “pure” metals and ceramics as well as mixtures of these, so called Functionally Gradient Materials. The main parameters used when developing a useful SPS method have been Force (to apply a selected pressure), Temperature and a selection of ON/OFF pulses ratio.
Now since a couple of years, Suga Co Ltd. of Japan has introduced a new degassing function, whereby the powders can be cleaned from moisture and/or impurities in a pre-process inside the closed SPS chamber before the actual sintering process commences. This can be done with temperature control via either Thermocouple or Pyrometer. Step-wise degassing at successively increasing temperatures is also possible and can be tailored for each specific powder sample’s needs. Purifying the powder before applying the sintering Pressure and Temperature ramp can help avoid inclusions and cracks and also facilitate reaching the highest densities and the ideal grain size and grain size distribution.
In addition to the conventional ON/OFF pulses, of which the effect is generally well known, we can now also apply a Full Wave current and a plain DC current. The effects of these parameters are different for metals and ceramics respectively and allow new optimisation possibilities in the materials research. Since metals and ceramics have very different electrical resistances (also with discernible differences within these groups), heat development in both the graphite mould/punches and inside the powder itself will vary, and this can be utilised by selecting other wave forms instead of the standard and conventional ON/OFF function. Several examples to illustrate these new and valuable functions will be presented at the conference.
Another trend in SPS development has been to apply higher forces and more current to produce larger pieces as well as several pieces in parallel in a single specially designed mould. This to eventually introduce SPS as a manufacturing technology. There is also another development within some fields of research, namely seeking to employ as small amounts as possible of the relevant sample powders. This is sought for several reasons – powders can be difficult to manufacture, expensive and/or even toxic. With the sensitivity of the new SUGA SPS 2000, a 100 mg Ni metal sample can be sintered in a 5 mm die to full density and with very clear densification trace. It should ideally be the size needed for ensuing evaluation of the sintered pellet that decides the sample size, not an inherent limitation to the SPS machine employed.