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Simultaneous Spark Plasma Sintering of Multiple Complex Shapes.

Charles Manière1, Elisa Torresani2, Eugene A Olevsky3,4

  • 1Powder Technology Laboratory, Department of Mechanical Engineering, San Diego State University, San Diego, CA 92182, USA. charles.maniere@ensicaen.fr.

Materials (Basel, Switzerland)
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Summary

This study introduces a new method for spark plasma sintering (SPS) complex nickel gears, enabling simultaneous production of multiple parts. The process ensures homogeneous densification and near net shape fabrication with a refined microstructure.

Keywords:
complex shapesdeformed interface methodenergy efficientmultiphysics simulationmultiple partsspark plasma sintering

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Powder Metallurgy

Background:

  • Spark Plasma Sintering (SPS) faces challenges in sintering complex shapes and producing multiple parts simultaneously.
  • Conventional SPS methods struggle with uniform densification for intricate geometries and multi-part production.

Purpose of the Study:

  • To develop a novel SPS method for concurrent sintering of complex-shaped components.
  • To address the limitations of SPS in producing multiple parts and intricate designs efficiently.

Main Methods:

  • A controllable interface method using a graphite deformable sub-mold was employed for simultaneous densification of two nickel gear shapes.
  • An energy-efficient SPS configuration utilizing an electric current below 900 A was developed for a large-scale powder assembly.
  • Electro-thermal-mechanical (ETM) simulations were conducted to analyze process stability and optimize densification conditions.

Main Results:

  • The developed graphite sub-mold facilitated mutual densification of complex nickel gear parts within a 40 mm deformation space.
  • ETM simulations indicated that incorporating alumina powder at interfaces ensured homogeneous densification, efficient heating, and thermal confinement.
  • The feasibility of fabricating two near net shape gears with a highly homogeneous microstructure was successfully demonstrated.

Conclusions:

  • The novel SPS approach overcomes challenges in sintering complex shapes and multi-part production.
  • The controllable interface method and optimized SPS configuration enable efficient and stable fabrication of intricate components.
  • This research paves the way for advanced manufacturing of complex metallic parts with superior microstructural integrity.