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Localized Overheating Phenomena and Optimization of Spark-Plasma Sintering Tooling Design.

Diletta Giuntini1, Eugene A Olevsky2,3, Cristina Garcia-Cardona4

  • 1Department of Mechanical Engineering, College of Engineering, San Diego State University, 5500 Campanile Dr., San Diego, CA 92182, USA. diletta.giuntini@gmail.com.

Materials (Basel, Switzerland)
|August 17, 2017
PubMed
Summary

This study models Spark Plasma Sintering (SPS) tooling overheating using finite element analysis. Simulations identified optimal tooling geometry to prevent excessive temperatures during the SPS process.

Keywords:
Field Assisted Sintering (FAST)Spark Plasma Sintering (SPS)finite elementmodelingoverheatingtemperature distribution

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Area of Science:

  • Materials Science and Engineering
  • Computational Materials Science
  • Manufacturing Processes

Background:

  • Spark Plasma Sintering (SPS) is a widely used technique for materials consolidation.
  • Tooling overheating is a critical issue that can limit SPS process efficiency and material quality.
  • Existing modeling approaches may not fully capture the coupled physics involved in SPS tooling behavior.

Purpose of the Study:

  • To develop and apply a 3D coupled electrical, thermal, and mechanical finite element model for Spark Plasma Sintering (SPS).
  • To investigate the causes of tooling overheating during SPS experiments.
  • To optimize SPS tooling design to mitigate overheating issues.

Main Methods:

  • A macro-scale finite element modeling framework was developed using COMSOL™ software.
  • The model incorporated coupled physics: Joule heating, heat transfer, mechanical conditions, and densification.
  • Simulations were performed on various tooling configurations with modified spacer geometries.

Main Results:

  • The finite element simulations successfully predicted temperature spatial distributions within graphite press-forms (dies, punches, spacers).
  • The analysis identified specific temperature peaks and their timing related to tooling geometry.
  • Modeling revealed that adjusting spacer radii can effectively reduce overheating.

Conclusions:

  • The developed finite element model provides a robust tool for analyzing SPS processes and optimizing tooling design.
  • Geometric modifications of SPS tooling, specifically the use of step-wise increasing radii spacers, can prevent overheating.
  • This approach offers a pathway for broader application in optimizing various SPS procedures and resolving thermal management challenges.