Effect of Nitrogen Atmosphere Annealing of Alloyed Powders on the Microstructure and Properties of ODS Ferritic Steels

Oxide Dispersion Strengthened (ODS) ferritic steels are promising materials for the nuclear power sector. This paper presents the results of a study on the sintering process using the Spark Plasma Sintering (SPS) technique, focusing on ODS ferritic steel powders with different contents (0.3 and 0.6 vol.%) of Y2O3. The novelty lies in the analysis of the effect of pre-annealing treatment on powders previously prepared by mechanical alloying on the microstructure, mechanical, and thermal properties of the sinters. Using the SPS method, it was possible to obtain well-densified sinters with a relative density above 98%. Pre-annealing the powders resulted in an increase in the relative density of the sinters and a slight increase in their thermal conductivity. The use of low electron energies during SEM analysis allowed for a fairly good visualization of the reinforcing oxides uniformly dispersed in the matrix. Analysis of the Mössbauer spectroscopy results revealed that pre-annealing induces local atomic rearrangements within the solid solution. In addition, there was an additional spectral component, indicating the formation of a Cr-based paramagnetic phase. The ODS material with a higher Y2O3 content showed increased Vickers hardness values, as well as increased Young's modulus and nanohardness, as determined by nanoindentation tests.

Effect of Metal Elements on Microstructure and Mechanical Properties of Ultrafine Cemented Carbide Prepared by SPS

To satisfy the needs of precision machining, ultrafine tungsten carbide (WC)-based cemented carbide with fine grain size and excellent mechanical properties was prepared. Ultrafine cemented carbide was prepared by spark plasma sintering (SPS) using WC, Co as raw materials and metal elements V, and Cr as additives, and the effects of metal elements on the microstructure and mechanical properties of cemented carbide were investigated. The results show that the specimen (91.6WC-1.2V-1.2Cr-6Co) prepared at 1350 °C, 6 min, 25 MPa has the best mechanical properties (HV 2322.9, KIC 8.7 MPa·m1/2) and homogeneous microstructure. The metal elements could react with WC to form a (W, V, Cr) Cx segregation layer, which effectively inhibits the growth of WC grains (300 nm). The combination of SPS and metal element additives provides a new approach for the preparation of ultrafine cemented carbides with excellent properties.

Nano-Structure Evolution and Mechanical Properties of AlxCoCrFeNi2.1 (x = 0, 0.3, 0.7, 1.0, 1.3) High-Entropy Alloy Prepared by Mechanical Alloying and Spark Plasma Sintering

The AlxCoCrFeNi2.1 (x = 0, 0.3, 0.7, 1.0, 1.3) multi-component high-entropy alloy (HEA) was synthesized by mechanical alloying (MA) and Spark Plasma Sintering (SPS), The impact of the percentage of Al on crystal structure transition, microstructure evolution and mechanical properties were studied. Crystal structure was investigated by X-ray Diffraction (XRD) and Scanning Electron Microscopy (SEM). The results show that with the increasing of Al content, the crystal structure of the alloys gradually transformed from a nanocrystalline phase of FCC to a mix of FCC and BCC nanocrystalline. The hardness was found to increase steadily from 433 HV to 565 HV due to the increase in fraction of BCC nanocrystalline phase. Thus, the compressive fracture strength increased from 1702 MPa to 2333 MPa; in contrast, the fracture strain decreased from 39.8% to 15.6%.

Electrochemical Performance and Microstructure Evolution of a Quasi-Solid-State Lithium Battery Prepared by Spark Plasma Sintering

Solid-state lithium batteries are promising next-generation energy storage systems for electric vehicles due to their high energy density and high safety and require achieving and maintaining intimate solid-solid interfaces for lithium-ion and electron transport. However, the solid-solid interfaces may evolve over cycling, disrupting the ion and electron diffusion pathways and leading to rapid performance degradation. The development of solid-state lithium batteries has been hindered by the lack of fundamental understanding of the interfacial microstructure change over cycling and its relation to electrochemical properties. Herein, we prepared a quasi-solid-state lithium battery, 30%LiFePO4-55%Li1.5Al0.5Ge1.5(PO4)3-15%C| Li1.5Al0.5Ge1.5(PO4)3|Li, by spark plasma sintering, and employed it as a model system to reveal the microstructure evolution at the solid-solid interfaces with electrochemical performance of the batteries. The electrochemical assessment showed that the quasi-solid-state lithium battery exhibited a discharge specific capacity of about 150 mAh g-1 in the first 80 cycles and then experienced severe capacity attenuation afterward, accompanied by a gradual internal resistance increase. Scanning electron microscopy observation showed that more cracks were formed inside the solid-state electrolyte and at the solid-solid interfaces as the battery cycled from 10 to 67 and 157 cycles. Detailed microstructure and phase analysis by high-resolution transmission electron microscopy and selected area electron diffraction discovered that the crack formation and performance decay were mainly caused by (1) the volume change of the LiFePO4 composite cathode during cycling, (2) the grain expansion of the Li1.5Al0.5Ge1.5(PO4)3 solid-state electrolyte at its interface with lithium anode, and (3) the formation of a solid electrolyte interphase layer, comprising Li2CO3, LiF, and LiTFSI, at the cathode-solid-state electrolyte interface. These microstructure changes built up over repeated battery cycling, ultimately causing the structure collapse and battery failure. The microstructure evolution information is expected to guide the design of better structures and interfaces for solid-state lithium batteries.

Production of Mn-Ga Magnets

Mn-based magnets are known to be a candidate for use as rare-earth-free magnets. In this study, Mn-Ga bulk magnets were successfully produced by hot pressing using the spark plasma sintering method on Mn-Ga powder prepared from rapidly solidified Mn-Ga melt-spun ribbons. When consolidated at 773 K and 873 K, the Mn-Ga bulk magnets had fine grains and exhibited high coercivity values. The origin of the high coercivity of the Mn-Ga bulk magnets was the existence of the D022 phase. The Mn-Ga bulk magnet consolidated at 873 K exhibited the highest coercivity of 6.40 kOe.

Fabrication and structural and magnetic properties of spark plasma sintered group-IV diluted magnetic semiconductor Fe-doped SiGe alloys

Fe-doped SiGe bulk alloys are fabricated using non-equilibrium spark plasma sintering (SPS) and their structure and ferromagnetic and magneto-transport properties are investigated. X-ray diffraction and high-resolution transmission electron microscope measurements show that the obtained alloys are composed of SiGe polycrystals. Magnetization measurements reveal that the Fe-doped SiGe alloys exhibit ferromagnetism up to 259 K, and their Curie temperature increases with Fe doping concentration up to 8%. Moreover, transport measurements of the Fe-doped SiGe alloys show typical metal-insulator transition characteristics of doped semiconductors as well as anomalous Hall effect and intriguing positive-to-negative magnetoresistance, indicating that the obtained alloys are diluted magnetic semiconductors (DMSs). Our results provide insight into the SPS-prepared Fe-doped SiGe bulk alloys and may be useful for the design, fabrication, and application of group-IV DMSs.

High-Entropy Diborides-Silicon Carbide Composites by Reactive and Non-Reactive Spark Plasma Sintering: A Comparative Study

The reactive spark plasma sintering (R-SPS) method was compared in this work with the two-step SHS-SPS route, based on the combination of the self-propagating high-temperature synthesis (SHS) with the SPS process, for the fabrication of dense (Hf0.2Mo0.2Ti0.2Ta0.2Nb0.2)B2-SiC and (Hf0.2Mo0.2Ti0.2Ta0.2Zr0.2)B2-SiC ceramics. A multiphase and inhomogeneous product, containing various borides, was obtained at 2000 °C/20 min by R-SPS from transition metals, B4C, and Si. In contrast, if the same precursors were first reacted by SHS and then processed by SPS under the optimized condition of 1800 °C/20 min, the desired ceramics were successfully attained. The resulting sintered samples possessed relative densities above 97% and displayed uniform microstructures with residual oxide content <2.4 wt.%. The presence of SiC made the sintering temperature milder, i.e., 150 °C below that needed by the corresponding additive-free system. The fracture toughness was also markedly improved, particularly when considering the Nb-containing system processed at 1800 °C/20 min, whereas the fracture toughness progressively decreased (from 7.35 to 5.36 MPa m1/2) as the SPS conditions became more severe. SiC addition was found to inhibit the volatilization of metal oxides like MoO3 formed during oxidation experiments, thus avoiding mass loss in the ceramics. The benefits above also likely took advantage of the fact that the two composite constituents were synthesized in parallel, according to the SHS-SPS approach, rather than being produced separately and combined subsequently, so that strong interfaces between them were formed.

Low Thermal Conductivity and High Thermoelectric Performance of Nb-Doped Quarternary Mixed Crystal Nb0.05W0.95-xMox(Se1-xSx)2

Transition-metal dichalcogenide WSe2 has attracted increasing interest due to its large thermopower (S), low-cost, and environment-friendly constituents. However, its thermoelectric figure of merit, ZT, of WSe2 is limited due to its large lattice thermal conductivity (κL) and low electrical conductivity. In view of WSe2 and MoS2 having the same crystal structure, here we designed and prepared Nb-doped quarternary mixed crystal (MC) Nb0.05W0.95-xMox(Se1-xSx)2 (0 ≤ x ≤ 0.095). The results indicate that the κL of the MC can reach as low as 0.12 W m K-1 at 850 K, being 93% smaller than that of WSe2. Our analysis reveals that its low κL originates chiefly from intense scattering of both high-frequency phonons from point defects (mainly alloying elements) and mid/low-frequency phonons from MoS2 inclusions residual within MC. In addition, the alloying of WSe2 with MoS2 causes a 5-fold increase in cation vacancies (VW‴'), leading to a large increase in hole concentration and electrical conductivity, which gives rise to a ∼7.5 times increase in power factor (reaching 4.2 μ W cm-1 K-2 at 850 K). As a result, a record high ZTmax = 0.63 is achieved at 850 K for the MC sample with x = 0.076, which is 20 times larger than that of WSe2, demonstrating that MC Nb0.05W0.95-xMox(Se1-xSx)2 is a promising thermoelectric material.

Study on the Effect of Sn, In, and Se Co-Doping on the Thermoelectric Properties of GeTe

GeTe and Ge0.99-xIn0.01SnxTe0.94Se0.06 (x = 0, 0.01, 0.03, and 0.06) samples were prepared by vacuum synthesis combined with spark plasma sintering (SPS). The thermoelectric properties of GeTe were coordinated by multiple doping of Sn, In, and Se. In this work, a maximum zT(zT = S2σT/κ) of 0.9 and a power factor (PF = S2σ) of 3.87 μWmm-1 K-2 were obtained in a sample of Ge0.99In0.01Te0.94Se0.06 at 723K. The XRD results at room temperature show that all samples are rhombohedral phase structures. There is a peak (~27°) of the Ge element in GeTe and the sample (x = 0), but it disappears after Sn doping, indicating that Sn doping can promote the dissolution of Ge. The scattering mechanism of the doped samples was calculated by the conductivity ratio method. The results show that phonon scattering Is dominant in all samples, and alloy scattering is enhanced with the increase in the Sn doping amount. In doping can introduce resonance energy levels and increase the Seebeck coefficient, and Se doping can introduce point defects to suppress phonon transmission and reduce lattice thermal conductivity. Therefore, the thermoelectric properties of samples with x = 0 improved. Although Sn doping will promote the dissolution of Ge precipitation, the phase transition of the samples near 580 K deteriorates the thermoelectric properties. The thermoelectric properties of Sn-doped samples improved only at room temperature to ~580 K compared with pure GeTe. The synergistic effect of multi-element doping is a comprehensive reflection of the interaction between elements rather than the sum of all the effects of single-element doping.

Study of Lightweight Ceramic Matrix-Less Syntactic Foam Composed of Cenosphere Using Spark Plasma Sintering

The current investigation presents porous ceramic materials prepared with cenospheres (CS) by using spark plasma sintering. The impact of sintering temperature, mould diameter (20, 30 and 50 mm) and cenosphere size on the properties of the sintered material was investigated. Shrinkage of the samples during sintering started at 900 °C. Total sample shrinkage during sintering increases with increasing temperature and decreases with increasing mould size; increasing sample sintering temperature increases the apparent density of all sample series CS 63-150 µm in a 20 mm mould from 0.97 to 2.3 g·cm-3 at 1050-1300 °C; in a 30 mm mould, 0.81-1.87 g·cm-3 at 1050-1200 °C; in 50 mm mould, 0.54-0.75 g·cm-3 at 1050-1150 °C; while CS 150-250 µm in a 20 mm mould is 0.93-1.96 g·cm-3 at 1050-1200 °C. Total porosity decreases from 61.5% to 3.9% by increasing sintering temperature from 1050 to 1250 °C, while open porosity reduces at lower temperatures, with closed porosity being highest in samples sintered at 1150 °C. When the sintering temperature increases from 1050 to 1300 °C, the compressive strength of the CS 63-150 samples produced in a 20 mm mould increases from 11 MPa to 312 MPa. These results correlate with the Rice model, which describes an exponential dependence of compressive strength on material porosity and fully dense material compressive strength.

Regulated Phase Separation in Al-Ti-Cu-Co Alloys through Spark Plasma Sintering Process

With the goal of developing lightweight Al-Ti-containing multicomponent alloys with excellent mechanical strength, an Al-Ti-Cu-Co alloy with a phase-separated microstructure was prepared. The granulometry of metal particles was reduced using planetary ball milling. The particle size of the metal powders decreased as the ball milling time increased from 5, 7, to 15 h (i.e., 6.6 ± 6.4, 5.1 ± 4.3, and 3.2 ± 2.1 μm, respectively). The reduction in particle size and the dispersion of metal powders promoted enhanced diffusion during the spark plasma sintering process. This led to the micro-phase separation of the (Cu, Co)2AlTi (L21) phase, and the formation of a Cu-rich phase with embedded nanoscale Ti-rich (B2) precipitates. The Al-Ti-Cu-Co alloys prepared using powder metallurgy through the spark plasma sintering exhibited different hardnesses of 684, 710, and 791 HV, respectively, while maintaining a relatively low density of 5.8-5.9 g/cm3 (<6 g/cm3). The mechanical properties were improved due to a decrease in particle size achieved through increased ball milling time, leading to a finer grain size. The L21 phase, consisting of (Cu, Co)2AlTi, is the site of basic hardness performance, and the Cu-rich phase is the mechanical buffer layer between the L21 and B2 phases. The finer network structure of the Cu-rich phase also suppresses brittle fracture.

Characterization of LaFeO3 Dielectric Ceramics Produced by Spark Plasma Sintering

Commercially available LaFeO3 powder was processed using the spark plasma sintering (SPS) technique. The results of the dielectric measurement showed high permittivity, but this was strongly frequency-dependent and was also accompanied by a high loss tangent. The chemical purity of the powder and changes induced by the SPS process influenced the stability of the dielectric parameters of the bulk compacts. A microstructure with a homogeneous grain size and a certain porosity was produced. The microhardness of the sintered LaFeO3 was rather high, about 8.3 GPa. All the results are in reasonable agreement with the literature related to the production of LaFeO3 using different techniques. At frequencies as low as 100 Hz, the material behaved like a colossal permittivity ceramic, but this character was lost with the increasing frequency. On the other hand, it exhibited persistent DC photoconductivity after illumination with a standard bulb.

Enhancing the Properties of Yttria-Stabilized Zirconia Composites with Zeolitic Imidazolate Framework-Derived Nanocarbons

Ceramic matrix composites (CMCs) reinforced with nanocarbon have attracted significant interest due to their potential to enhance mechanical, thermal, and electrical properties. Although the investigation of carbon-based materials such as graphene and carbon nanotubes as additives for advanced ceramics has been widespread, the utilization of metal-organic framework (MOF)-derived nanocarbons in CMCs remains largely unexplored. We extended our previous proof-of-concept investigations by demonstrating the effectiveness of a different type of MOF-derived carbon as a reinforcing phase in an alternative ceramic matrix. We employed spark plasma sintering (SPS) to consolidate yttria-stabilized zirconia (YSZ) and zeolitic imidazolate framework (ZIF-67) powder blends at 1300 °C and a uniaxial pressure of 50 MPa. YSZ serves as the ceramic matrix, whereas ZIF-67 serves as the nanocarbon source. The composite exhibits a highly significant improvement in fracture toughness with an increase of up to 13% compared to that of the YSZ monolith. The formation of ZIF-derived nanocarbon interlayers is responsible for the observed enhancement in ductility, which can be attributed to their ability to facilitate energy dissipation during crack propagation and inhibit grain growth. Furthermore, the room-temperature electrical conductivity of the sintered samples demonstrates a substantial improvement, primarily due to the in situ formation of nanocarbon-based fillers, reaching an impressive 27 S/m with 10 wt % ZIF-67 content. Based on the results, it can be inferred that the incorporation of in situ MOF-derived nanocarbons into CMCs leads to a substantial improvement in both the mechanical and electrical properties.

Metal Scrap to Hydrogen: Manufacture of Hydroreactive Solid Shapes via Combination of Ball Milling, Cold Pressing, and Spark Plasma Sintering

Two sorts of tablets were manufactured from ball-milled powder (aluminum scrap and copper) by cold pressing and spark plasma sintering. Their microstructure, phase, and elemental compositions were investigated via scanning electron microscopy, X-ray diffraction analysis, and energy-dispersive X-ray spectroscopy. New phases, Al2Cu and MgCuAl2, were detected in the samples. Their microstructure was formed by welded scrap particles, the intermetallides, and Cu-rich regions located majorly along 'interparticle boundaries' and, to a lesser extent, within small, micro- and nanosized 'intraparticle spots'. The tablets were sealed with adhesive, so only the top surface was exposed to the environment, and tested in a chlorine aqueous solution for hydrogen generation performance. For both sample sorts, hydrogen yields of nearly 100% were achieved. The sintered tablets reacted faster than the cold-pressed ones: at 60, 70, and 80 °C, their entire 'conversion into hydrogen' took ~80, 40, and 30 min. vs. ~220, 100, and 70 min. The experimental kinetic curves were fitted with a contracting geometry equation, and those for the sintered samples were approximated with higher precision. The key effect of the additive was to enhance hydrogen evolution through the galvanic corrosion of Al in the regions adjacent to the intermetallic inclusions and Cu-rich spots.

Preparation and Characteristics of High-Performance, Low-Density Metallo-Ceramics Composite

By applying the physical vapour deposition method, hollow ceramic microspheres were coated with titanium, and subsequently, they were sintered using the spark plasma sintering technique to create a porous ceramic material that is lightweight and devoid of a matrix. The sintering process was carried out at temperatures ranging from 1050 to 1200 °C, with a holding time of 2 min. The samples were subjected to conventional thermal analyses (differential scanning calorimetry, thermogravimetry, dilatometry), oxidation resistance tests, and thermal diffusivity measurements. Phase analysis of the samples was performed using the XRD and the microstructure of the prepared specimens was examined using electron microscopy. The titanium coating on the microspheres increased the compressive strength and density of the resulting ceramic material as the sintering temperature increased. The morphology of the samples was carefully examined, and phase transitions were also identified during the analysis of the samples.

Spark Plasma Sintering of Fine-Grained WC-Co Composites

Cemented carbides WC-Co are one of the basic tool materials. They constitute over half of the currently used tools intended for machining. The main advantages of WC-Co cemented carbides are high hardness and abrasion resistance. The properties of WC-Co sinters depend mainly on the content of the binding phase, the sintering method and the grain size of the powder from which the sinters were made. The aim of this study was to produce fine-grained WC-Co composites using SPS (spark plasma sintering) technology, as well as examine the effect of the applied technology on the basic properties of WC-Co sinters: microstructure, hardness, phase composition, compaction degree and tribological properties. In the processes carried out, no additives affecting the reduction in grain growth were used. Sintering was conducted at a temperature of 1200 °C with a holding time of 10 min. The process occurred under a load of 100 MPa. Finally, the samples were cooled in a vacuum of 10-6 mbar. We measured the hardness using a Vickers hardness tester. We took hardness measurements along the diameter of the sintered samples. In order to ascertain the fracture toughness (KIC), we measured the radial crack length around the Vickers indentation and applied Shetty's formula. The tribological tests were carried out with a tribotester using the T-01 ball-on-disc method. The obtained data enabled the characterization of the wear process of the tested materials.

Study of Structural, Compression, and Soft Magnetic Properties of Fe65Ni28Mn7 Alloy Prepared by Arc Melting, Mechanical Alloying, and Spark Plasma Sintering

Soft magnetic Fe65Ni28Mn7 (at. %) alloy was successfully synthesized by mechanical alloying and spark plasma sintering (SPS) and, in parallel, the same composition was prepared by arc melting (AM) for comparison. Several SPS conditions were tested. X-ray diffraction and scanning electron microscopy were used to investigate the structure, phase composition, and morphology of the samples. It was found that mechanical alloying produced BCC and FCC supersaturated solid solution after 130 h of milling, with a fine microstructure (i.e., crystallite size of 10 nm). Spark plasma sintering performed at 750 °C and 1000 °C under two pressures of 50 MPa and 75 MPa revealed stable FCC phases. A single FCC phase was observed after the arc melting synthesis. The magnetic properties of milled powders and solids obtained by AM and SPS were investigated. The specimen consolidated by SPS at 1000 °C under the pressure of 50 MPa exhibits soft magnetic behavior (coercivity 0.07 Oe), whereas the mechanically alloyed sample revealed hard magnetic behavior. The specimen consolidated at 750 °C under a pressure of 75 MPa showed a higher compressive strength of 1700 MPa and a Vickers hardness of 425 ± 18 HV. As a result, sintering at 750 °C/75 MPa can be utilized to enhance the mechanical properties, while those sintered at 1000 °C/50 MPa increase magnetic softness.

Mg Compensating Design in the Melting-Sintering Method For High-Performance Mg3 (Bi, Sb)2 Thermoelectric Devices

N-type Mg3 (Bi, Sb)2 -based thermoelectric (TE) alloys show great promise for solid-state power generation and refrigeration, owing to their excellent figure-of-merit (ZT) and using cheap Mg. However, their rigorous preparation conditions and poor thermal stability limit their large-scale applications. Here, this work develops an Mg compensating strategy to realize n-type Mg3 (Bi, Sb)2 by a facile melting-sintering approach. "2D roadmaps" of TE parameters versus sintering temperature and time are plotted to understand the Mg-vacancy-formation and Mg-diffusion mechanisms. Under this guidance, high weight mobility of 347 cm2  V-1  s-1 and power factor of 34 µW cm-1  K-2 can be obtained for Mg3.05 Bi1.99 Te0.01 , and a peak ZT≈1.55 at 723 K and average ZT≈1.25 within 323-723 K can be obtained for Mg3.05 (Sb0.75 Bi0.25 )1.99 Te0.01 . Moreover, this Mg compensating strategy can also improve the interfacial connecting and thermal stability of corresponding Mg3 (Bi, Sb)2 /Fe TE legs. As a consequence, this work fabricates an 8-pair Mg3 Sb2 -GeTe-based power-generation device reaching an energy conversion efficiency of ≈5.0% at a temperature difference of 439 K, and a one-pair Mg3 Sb2 -Bi2 Te3 -based cooling device reaching -10.7 °C at the cold side. This work paves a facile way to obtain Mg3 Sb2 -based TE devices at low cost and also provides a guide to optimize the off-stoichiometric defects in other TE materials.

Structure and Properties of High-Entropy Boride Ceramics Synthesized by Mechanical Alloying and Spark Plasma Sintering

This manuscript shows the study of the structure, mechanical, and chemical properties of high-entropy borides MeB2 (Me = Ti, Ta, Nb, Hf, Zr). High-entropy borides were synthesized by mechanical alloying and spark plasma sintering. A chemically homogeneous powder with a low iron content (0.12%) was obtained in a planetary mill by rotating the planetary disk/pots at 200-400 rpm and a processing time of 7.5 h. The structure, mechanical, and chemical properties of the resulting high-entropy borides have been studied. A single-phase hexagonal structure is formed during spark plasma sintering of mechanically alloyed powders at 2000 °C. The microhardness of the samples ranged from 1763 to 1959 HV. Gas-dynamic tests of the synthesized materials showed that an increase in the content of Zr and Hf in the composition increases the thermal-oxidative resistance of the material.

Selective Laser Melting and Spark Plasma Sintering: A Perspective on Functional Biomaterials

Achieving lightweight, high-strength, and biocompatible composites is a crucial objective in the field of tissue engineering. Intricate porous metallic structures, such as lattices, scaffolds, or triply periodic minimal surfaces (TPMSs), created via the selective laser melting (SLM) technique, are utilized as load-bearing matrices for filled ceramics. The primary metal alloys in this category are titanium-based Ti6Al4V and iron-based 316L, which can have either a uniform cell or a gradient structure. Well-known ceramics used in biomaterial applications include titanium dioxide (TiO2), zirconium dioxide (ZrO2), aluminum oxide (Al2O3), hydroxyapatite (HA), wollastonite (W), and tricalcium phosphate (TCP). To fill the structures fabricated by SLM, an appropriate ceramic is employed through the spark plasma sintering (SPS) method, making them suitable for in vitro or in vivo applications following minor post-processing. The combined SLM-SPS approach offers advantages, such as rapid design and prototyping, as well as assured densification and consolidation, although challenges persist in terms of large-scale structure and molding design. The individual or combined application of SLM and SPS processes can be implemented based on the specific requirements for fabricated sample size, shape complexity, densification, and mass productivity. This flexibility is a notable advantage offered by the combined processes of SLM and SPS. The present article provides an overview of metal-ceramic composites produced through SLM-SPS techniques. Mg-W-HA demonstrates promise for load-bearing biomedical applications, while Cu-TiO2-Ag exhibits potential for virucidal activities. Moreover, a functionally graded lattice (FGL) structure, either in radial or longitudinal directions, offers enhanced advantages by allowing adjustability and control over porosity, roughness, strength, and material proportions within the composite.

Effect of Doping with Different Nb Contents on the Properties of CoCrFeNi High-Entropy Alloys

A series of five-element CoCrFeNi-Nbx (x = 0, 1, 3, 5, 7, and 9 wt%) high-entropy alloys were prepared using high-energy ball milling and discharge plasma sintering methods. Then, the effects of doping with Nb elements on the organization and properties of the CoCrFeNi HEAs were systematically investigated by tensile testing, hardness testing, and examining their micro-morphologies. The results show that with the addition of the Nb element, the lattice distortion of the alloy due to the large size of the Nb atoms causes the microstructure of CoCrFeNi HEAs to change from a single-phase FCC structure to a dual-phase structure of FCC and Laves. With the increase in the Nb content, the increase in the volume fraction of the hard and brittle Laves phase leads to the enhancement of the HEA's tensile strength, yield strength, and hardness, and a decrease in plasticity. The Nb5 alloy showed the most excellent comprehensive performance, with a tensile strength, yield strength, and plasticity of 879.1 MPa, 491.8 MPa, and 39.8%, respectively, and all the properties were improved compared with those of the HEAs obtained by the arc melting method. The increase in the hardness of the HEAs was nearly proportional to the increase in the volume fraction of the Laves phase, which was the direct cause of the increase in the hardness of the HEA. Therefore, since the Laves phase is the direct cause of the increase in HEA hardness, the doping of CoCrFeNi HEAs with Nb can significantly improve the properties of HEAs.

CoxCrFeNiTi High-Entropy Alloys Prepared via Mechanical Alloying and Spark Plasma Sintering for Magnetron Sputtering Coatings

The main objective of this study was to develop a high-entropy alloy (HEA) derived from the CoxCrFeNiTi HEA system (x = 0.5, 1) for protective coatings using the magnetron sputtering method. In order to produce the high-entropy alloy targets required for the magnetron sputtering process, mechanically alloyed metallic powders were consolidated via spark plasma sintering (SPS). The microstructural analysis results of the HEA mixture presented morphology changes after 30 h of alloying, with the particles presenting uniform polygonal shapes and dimensions. Subsequently, 316L stainless steel (SS) specimens were coated via magnetron sputtering, comparing their composition with that of the sputtering targets used for deposition to establish stoichiometry. Microstructural analyses of the SPSed HEAs revealed no defects and indicated a uniform elemental distribution across the surface. Furthermore, the CoCrFeNiTi equiatomic alloy exhibited a nearly stoichiometric composition, both in the coating and the sputtering target. The XRD analysis results indicated that amorphous coatings were obtained for both Co0.5CrFeNiTi and the CoCrFeNiTi HEA, and nanoindentation tests indicated that the CoCrFeNiTi HEA coating presented a hardness of 596 ± 22 HV, compared to the 570 ± 19 HV measured for Co0.5CrFeNiTi, suggesting an improved wear resistance.

Improvement in Abrasive Wear Resistance of Metal Matrix Composites Used for Diamond-Impregnated Tools by Heat Treatment

This work presents the possibilities of producing a substitute for a commercial matrix material for sintered metal-diamond tools which is characterized by increased tribological properties required in machining natural stones and concrete. In this study, the improvement in wear behavior of sintered pre-alloyed matrix caused by a thermal treatment was investigated. Several mixtures made of commercially available powders were homogenized by ball milling and consolidated at 900 °C using the spark plasma sintering (SPS) method. During cooling down, the specimens were subjected to isothermal holding at 350 or 250 °C for 1 h. After consolidation, all specimens were tested for density and hardness, whereas selected specimens were characterized by scanning electron microscopy (SEM) and flexural strength tests. The specimens made of BDCM50 powder (a mixture of the base and pre-alloyed powders in 50:50 proportion) shows excellent properties including σ0.2 = 1045 MPa in the three-point bending test and HV10 ≈ 380. Resistance to abrasive wear evaluated in both three-body and two-body conditions in the MWT abrasion test was estimated at Ai3=18.1±3.9 μm/20 m and Ai2=95.9±11.8 μm/20 m, respectively. A series of diamond-impregnated specimens (segments) was also produced and tested for wear rate on abrasive concrete. The potential graphitization of the diamond grits was investigated using Raman spectroscopy and X-ray diffraction. As a reference, both the base Fe-Mn-Cu-Sn-C and commercially available Co+20%WC alloy were used to compare selected properties of the investigated materials. It has been proved that heat-treated specimens made of the base mixture modified with pre-alloyed powders are characterized by increased hardness and resistance to abrasive wear. The BDCM50 matrix has a negligible effect on diamond graphitization and shows excellent field performance, which makes it a good potential substitute for replacing Co+20%WC in sintered diamond-impregnated tools.

Investigation of Spark Plasma Sintering on Microstructure-Properties of Zirconia Reinforced Fluormica Glass for Dental Restorations

BACKGROUND

Conventional sintering methods of dental ceramics have limitations of high temperature and slow cooling rates with requirements of additional heat treatment for crystallization. Spark plasma sintering (SPS) is an emerging technique that has the potential to process dental restorations with dense microstructures and tailor-made clinically relevant properties with optimized processing parameters. This study explored the potential of the SPS of zirconia-reinforced fluormica glass (FM) for dental restorative materials.

METHODS

FM glass frit was obtained through the melt-quench technique (44.5 SiO2-16.7 Al2O3-9.5 K2O-14.5 MgO-8.5 B2O3-6.3 F (wt.%)). The glass frit was ball-milled with 20 wt.% of 3 mol% yttria-stabilized zirconia (FMZ) for enhanced fracture toughness. The mixtures were SPS sintered at a pressure of 50 MPa and a heating rate of 100 °C/min for 5 min with an increase in temperature from 650-750 °C-850 °C-950 °C. Phase analysis was carried out using XRD and microstructural characterization with SEM. Micro-hardness, nano-indentation, porosity, density, indentation fracture toughness, and genotoxicity were assessed.

CONCLUSIONS

The increase in the SPS temperature of FMZ influenced its microstructure and resulted in reduced porosity, improved density, and optimal mechanical properties with the absence of genotoxicity on human gingival fibroblast cells.

Investigation of the Microstructure of Sintered Ti-Al-C Composite Powder Materials under High-Voltage Electrical Discharge

Dispersion-hardened materials based on TiC-AlnCn are alloys with high heat resistance, strength, and durability that can be used in aircraft and rocket technology as a hard lubricant. The titanium-rich composites of the Ti-Al-C system were synthesized via the spark plasma sintering process. Composite powder with 85% of Ti, 15% of Al, and MAX-phases was processed using high-voltage electrical discharge in kerosene at a specific energy of 25 MJ kg-1 to obtain nanosized particles. This method allows us to analyze the most efficient, energy saving, and less waste-generating technological processes producing materials with improved mechanical and physical properties. An Innova test indentation machine was used to determine the hardness of the synthesized composites. The microhardness of Ti-Al-C system samples was determined as approximately 500-600 HV. Scanning electron microscopy and energy-dispersive X-ray spectroscopy were performed to identify the hard titanium matrix reinforced by intermetallic phases and the clusters of carbides. Three types of reinforcing phases were detected existing in the composites-TiC, Al4C3, and Al3Ti, as well as a matrix consisting of α- and β-titanium. The lattice parameters of all phases detected in the composites were calculated using Rietveld analysis. It was determined that by increasing the temperature of sintering, the amount of aluminum and carbon increases in the carbides and intermetallic phases, while the amount of titanium decreases.

Properties of PBZTS Ferroelectric Ceramics Obtained Using Spark Plasma Sintering

In this paper, spark plasma sintering was used to obtain and investigate (Pb0.97Ba0.03)(Zr0.98Ti0.02)1-xSnxO3 (PBZTS) ceramic materials for x = 0, 0.02, 0.04, 0.06, and 0.08. Crystal structure, microstructure, dielectric and ferroelectric properties, and electrical conductivity tests of a series of samples were carried out. The SPS sintering method ensures favorable dielectric and ferroelectric properties of PBZTS ceramic materials. X-ray studies have shown that the material has a perovskite structure. The samples have a densely packed material structure with properly crystallized grains. The fine-grained microstructure of the PZBZTS material with high grain homogeneity allows the application of higher electric fields. Ceramic samples obtained by the SPS method have higher density values than samples obtained by the classical method (FS). The permittivity at room temperature is in the range of 245-282, while at the phase transition temperature is in the range of 10,259-12,221. At room temperature, dielectric loss factor values range from 0.006 to 0.036. The hysteresis loops of PBZTS ceramics have a shape typical for ferroelectric hard materials, and the remnant polarization values range from 0.32 to 0.39 µC/cm2. The activation energy Ea values of the PBZTS samples result mainly from the presence of oxygen vacancies. The PZT material doped with Ba and Sn and sintered via the SPS method has favorable physical parameters for applications in modern devices such as actuators or pulse capacitors.

Effect of Ball Milling Time on the Microstructure and Properties of High-Silicon-Aluminum Composite

The duration of ball milling greatly influences the characteristics of high-silicon-aluminum composite during the ball milling process. This study examines how the microstructure, thermal conductivity, and hardness of a high-silicon-aluminum composite are affected by different ball milling times. We exposed the powder to various durations of ball milling and employed different pellet ratios. Following this treatment, the powder underwent consolidation via discharge plasma sintering. Our findings show that with a pellet ratio of 10:1 and a milling duration of 8 h, the powder particles were refined, resulting in a more uniform and dense material composition. This refined material boasted a thermal conductivity of 111.6 W/m·K, a Brinell hardness of 136.8 HBW, and a density of 2.304 g/cm3. This method facilitates the creation of a uniform composite powder composition. It encourages the development of a fine-grain structure, which enables the production of particle-reinforced composites with superior properties.

Enhanced Mechanical Properties of Al2O3 Nanoceramics via Low Temperature Spark Plasma Sintering of Amorphous Powders

In this work, Al2O3 nanoceramics were prepared by spark plasma sintering of amorphous powders and polycrystalline powders with similar particle sizes. Effective comparisons of sintering processes and ultimate products depending on starting powder conditions were explored. To ensure near-full density higher than 98% of the Al2O3 nanoceramics, the threshold temperature in SPS is 1450 °C for polycrystalline Al2O3 powders and 1300 °C for amorphous powders. The low SPS temperature for amorphous powders is attributed to the metastable state with high free energy of amorphous powders. The Al2O3 nanoceramics prepared by amorphous powders display a mean grain size of 170 nm, and superior mechanical properties, including high bending strength of 870 MPa, Vickers hardness of 20.5 GPa and fracture toughness of 4.3 MPa∙m1/2. Furthermore, the Al2O3 nanoceramics prepared by amorphous powders showed a larger dynamic strength and dynamic strain. The toughening mechanism with predominant transgranular fracture is explained based on the separation of quasi-boundaries.

Effect of C Addition on the Microstructure and Fracture Properties of In Situ Laminated Nb/Nb5Si3 Composites

//Nbss and α-Nb5Si3 phases were detected. Meanwhile, Nb2C was observed, and the crystal forms of Nb5Si3 changed in the C-doped composites. Furthermore, micron-sized and nano-sized Nb2C particles were found in the Nbss layer. The orientation relationship of Nb2C phase and the surrounding Nbss was [001]Nbss//[010]Nb2C, (200) Nbss//(101) Nb2C. Additionally, with the addition of C, the compressive strength of the composites, at 1400 °C, and the fracture toughness increased from 310 MPa and 11.9 MPa·m1/2 to 330 MPa and 14.2 MPa·m1/2, respectively; the addition of C mainly resulted in solid solution strengthening.

Carbon Contamination Prevention during Spark Plasma Sintering

Carbon contamination from graphite molds during spark plasma sintering (SPS) considerably affects the properties of the sintered materials, especially transparent ceramics. Herein, transparent Y3Al5O12 (YAG) ceramics were prepared via SPS using Mo and Ta foils, separately and in tandem, as protective barriers against carbon contamination. The effects of Ta and Mo foils on the transparency and microstructure of the ceramics, and their protection mechanisms were studied. Experimental results show that a reaction layer formed at the Ta-YAG interface with a YTaO4-Al2O3 eutectic composition suppresses carbon penetration into the ceramic, increasing its transparency. By contrast, Mo foils, when used as protective barriers, allow carbon diffusion into the ceramic, resulting in the formation of nonuniform microstructural features. However, it does not form a reactive layer and, hence, is removed easily from the YAG surface. Multilayered Ta-Mo barrier exhibits improved outcomes if the Ta thickness is more than ∼100 μm. This behavior is attributed to the interior diffusion-blocking mechanism of Ta. Similar optical performance was demonstrated by both approaches. The results prove that carbon contamination in SPS-derived samples can be effectively prevented. Additionally, this study reports on a novel strategy of bonding oxide ceramics to metals by adding a Ta layer at the joint interface.

Optimization of Spark Plasma Sintering Technology by Taguchi Method in the Production of a Wide Range of Materials: Review

This paper reviews the production of sinters using the spark plasma sintering method. SPS (spark plasma sintering) technology has been used for several decades, mainly in laboratories, to consolidate a huge number of both new and traditional materials. However, it is now more often introduced into practical industrial use, with equipment as early as the fifth generation capable of producing larger-size components at competitive costs. Although the mechanism of sintering with the use of this method is not yet understood, the effectiveness of the SPS process for the rapid and efficient consolidation of a wide range of materials with novel micro-structures remains indisputable. With a relatively wide variation in chemical composition, the structure allows the selection of appropriate consolidation parameters for these materials. The influence on the values of apparent density and mechanical properties depends on the parameters of the spark plasma sintering process. In order to achieve a density close to the theoretical density of sinters, optimization of the sintering parameters, i.e., sintering temperature, heating rate, sintering time, pressing pressure and protective atmosphere, should be carried out. In this paper, the optimization of spark plasma sintering of Si3N4-Al2O3-ZrO2 composite was carried out using the Taguchi method. The effects of four sintering factors, namely heating rate, sintering time, sintering temperature and sintering pressure, on the final density were investigated. Optimal sintering conditions were proposed and a confirmation experiment was conducted. The optimal combination of sintering conditions for spark plasma sintering (SPS) of Si3N4-Al2O3-ZrO2 composite for high apparent density was determined as A3-B3-C3-D2. Based on ANOVA analysis, it was found that the apparent density of sintering was significantly influenced by sintering temperature, followed by pressing pressure, sintering time and heating rate. Validation of the developed mathematical model predicting the apparent density of sinters showed close agreement between the predicted response results and experimental results.

Synthesis of Tungsten Carbides in a Copper Matrix by Spark Plasma Sintering: Microstructure Formation Mechanisms and Properties of the Consolidated Materials

In this study, the synthesis of tungsten carbides in a copper matrix by spark plasma sintering (SPS) is conducted and the microstructure formation mechanisms of the composite materials are investigated. The reaction mixtures were prepared by the high-energy mechanical milling (MM) of W, C and Cu powders. The influence of the MM time and SPS temperature on the tungsten carbide synthesis in an inert copper matrix was analyzed. It was demonstrated that the milling duration is a critical factor for creating the direct contacts between the W and C reactants and increasing the reactive transformation degree. A WC-W2C-Cu composite was fabricated from the W-C-3Cu powder mixture milled for 10 min and subjected to SPS at a temperature of 980 °C for 5 min. The formation of unconventional microstructures with Cu-rich regions is related to inter-particle melting during SPS. The WC-W2C-Cu composite showed a promising combination of mechanical and functional properties: a hardness of 300 HV, an electrical conductivity of 24% of the International Annealed Copper Standard, a residual porosity of less than 5%, a coefficient of friction in pair with a WC-6Co counterpart of 0.46, and a specific wear rate of the material of 0.52 × 10-5 mm3 N-1 m-1.

Effect of HA Content on Microstructure and Properties of Ti-27Nb-17Ta-8Zr/HA Composite

In this paper, Ti-27Nb-17Ta-8Zr/HA series composite materials were prepared by spark plasma sintering (SPS) technology. The medical titanium alloy (Ti-27Nb-17Ta-8Zr) with good mechanical properties, wear resistance, and corrosion resistance was combined with the hydroxyapatite (HA) bioactive ceramic with high biological activity and bone-binding ability. Moreover, the density, microstructure evolution, metal/ceramic reaction, mechanical behavior, in vitro bioactivity, and influencing mechanisms of composite materials with different HA contents were studied. The research results indicate that all biological composite materials are composed of β-Ti solution, α-Ti, and ceramic phases (T_i2O, CaTiO₃, CaO, Ti_xP_y). With the increase of HA content, the compressive strength and yield strength of the composite material show a trend of first increasing, then decreasing, and then slowly increasing. After soaking in SBF artificial simulated body fluid for 5 days, the deposition of elements such as Ca and P on the surface significantly increased, while elements such as Ti, Nb, Ta, and Zr were evenly distributed in the matrix, demonstrating good in vitro mineralization ability and facilitating the attachment and growth of osteoblasts.

Microstructural and Mechanical Characterization of Colloidal Processed WC/(W5Vol%Ni) via Spark Plasma Sintering

This study investigates the sintering behaviour and properties of WC-based composites in which WC was mixed with W5vol%Ni in concentrations of 10vol% and 20vol%. Colloidal processing in water and spark plasma sintering were employed to disperse the WC particles and facilitate sintering. The addition of W5vol%Ni improved the sintering process, as evident from a lower onset temperature of shrinkage determined through dilatometric studies. All samples exhibited the formation of tungsten monocarbide (W₂C), with a more pronounced presence in the WC/20(W5vol%Ni) composite. Sintering reached its maximum rate at 1550 °C and was completed at 1600 °C, resulting in a final density exceeding 99.8%. X-ray diffraction analysis confirmed the detection of WC and W₂C phases after sintering. The observed WC content was higher than expected, which may be attributed to carbon diffusion during the process. Macro-scale mechanical characterisations revealed that the WC/10(W5vol%Ni) composite exhibited a hardness of 18.9 GPa, while the WC/20(W5vol%Ni) composite demonstrated a hardness of 18.3 GPa. Increasing the W5vol%Ni binder content caused a decrease in mechanical properties due to the formation of W₂C phases. This study provides valuable insights into the sintering behavior and properties of WC/W5vol%Ni composites, offering potential applications in extreme environments.

Morphological Analyses of W/Cu Functional Graded Materials Obtained by Conventional and Spark Plasma Sintering

The paper presents the analysis of two compaction methods for obtaining W/Cu Functional Graded Materials (FGMs) consisting of three layers with the following compositions (% weight): first layer 80 W/20 Cu, second layer 75 W/25 Cu, and third layer 65 W/35 Cu. Each layer composition was obtained using powders obtained through mechanical milling. The two compaction methods were Spark Plasma Sintering (SPS) and Conventional Sintering (CS). The samples obtained after the SPS and CS were investigated from morphological (scanning electron microscopy-SEM) and compositional (energy dispersive X-ray spectroscopy-EDX) points of views. Additionally, the porosities and the densities of each layer in both cases were studied. It was found that the densities of the sample's layers obtained through SPS are superior to those obtained through CS. The research emphasizes that, from a morphological point of view, the SPS process is recommended for W/Cu-FGMs, having raw materials as fine-graded powders against the CS process.

Numerical Simulation of Physical Fields during Spark Plasma Sintering of Boron Carbide

Spark plasma sintering is a new technology for preparing ceramic materials. In this article, a thermal-electric-mechanical coupled model is used to simulate the spark plasma sintering process of boron carbide. The solution of the thermal-electric part was based on the charge conservation equation and the energy conservation equation. A phenomenological constitutive model (Drucker-Prager Cap model) was used to simulate the densification process of boron carbide powder. To reflect the influence of temperature on sintering performance, the model parameters were set as functions of temperature. Spark plasma sintering experiments were conducted at four temperatures: 1500 °C, 1600 °C, 1700 °C, and 1800 °C, and the sintering curves were obtained. The parameter optimization software was integrated with the finite element analysis software, and the model parameters at different temperatures were obtained through the parameter inverse identification method by minimizing the difference between the experimental displacement curve and the simulated displacement curve. The Drucker-Prager Cap model was then incorporated into the coupled finite element framework to analyze the changes of various physical fields of the system over time during the sintering process.

Simultaneous Enhancement of the Power Factor and Phonon Blocking in Nb-Doped WSe2

Transition-metal dichalcogenide WSe₂ is a potentially good thermoelectric (TE) material due to its high thermopower (S). However, the low electrical conductivity (σ), power factor (PF), and relatively large lattice thermal conductivity (κ_L) of pristine WSe₂ degenerate its TE performance. Here, we show that through proper substitution of Nb for W in WSe₂, its PF can be increased by ∼10 times, reaching 5.44 μW cm^-1 K^-2 (at 850 K); simultaneously, κ_L lowers from 1.70 to 0.80 W m^-1 K^-1. Experiments reveal that the increase of PF originates from both increased hole concentration due to the replacement of W⁴⁺ by Nb³⁺ and elevated thermopower (S) caused by the enhanced density of states effective mass, while the reduced κ_L comes mainly from phonon scattering at point defects Nb_W. As a result, a record high figure of merit ZT_max ∼0.42 is achieved at 850 K for the doped sample W_0.95Nb_0.05Se₂, which is ∼13 times larger than that of pristine WSe₂, demonstrating that Nb doping at the W site is an effective approach to improve the TE performance of WSe₂.

CaSiO3-HAp Metal-Reinforced Biocomposite Ceramics for Bone Tissue Engineering

Reconstructive and regenerative bone surgery is based on the use of high-tech biocompatible implants needed to restore the functions of the musculoskeletal system of patients. Ti6Al4V is one of the most widely used titanium alloys for a variety of applications where low density and excellent corrosion resistance are required, including biomechanical applications (implants and prostheses). Calcium silicate or wollastonite (CaSiO₃) and calcium hydroxyapatite (HAp) is a bioceramic material used in biomedicine due to its bioactive properties, which can potentially be used for bone repair. In this regard, the research investigates the possibility of using spark plasma sintering technology to obtain new CaSiO₃-HAp biocomposite ceramics reinforced with a Ti6Al4V titanium alloy matrix obtained by additive manufacturing. The phase and elemental compositions, structure, and morphology of the initial CaSiO₃-HAp powder and its ceramic metal biocomposite were studied by X-ray fluorescence, scanning electron microscopy, energy-dispersive X-ray spectroscopy, and Brunauer-Emmett-Teller analysis methods. The spark plasma sintering technology was shown to be efficient for the consolidation of CaSiO₃-HAp powder in volume with a Ti6Al4V reinforcing matrix to obtain a ceramic metal biocomposite of an integral form. Vickers microhardness values were determined for the alloy and bioceramics (~500 and 560 HV, respectively), as well as for their interface area (~640 HV). An assessment of the critical stress intensity factor K_Ic (crack resistance) was performed. The research result is new and represents a prospect for the creation of high-tech implant products for regenerative bone surgery.

The Influence of Preparation Temperature on the Different Facets of Bulk MgB2 Superconductors

Two MgB₂ samples were prepared using the spark plasma sintering (SPS) technique at different temperatures-950 °C (S1) and 975 °C (S2)-for 2 h under 50 MPa pressure to study the influence of preparation temperature on different facets, namely those perpendicular (PeF) and parallel (PaF) to the compression direction of uniaxial pressure during the SPS of MgB₂ samples. We analyzed the superconducting properties of the PeF and PaF of two MgB₂ samples prepared at different temperatures from the curves of the critical temperature (T_C), the curves of critical current density (J_C), the microstructures of MgB₂ samples, and the crystal size from SEM. The values of the onset of the critical transition temperature, T_c,onset, were around 37.5 K and the transition widths were about 1 K, which indicates that the two samples exhibit good crystallinity and homogeneity. The PeF of the SPSed samples exhibited slightly higher J_C compared with that of the PaF of the SPSed samples over the whole magnetic field. The values of the pinning force related to parameters h₀ and K_n of the PeF were lower than those of the PaF, except for K_n of the PeF of S1, which means that the PeF has a stronger GBP than the PaF. In low field, the most outstanding performance was S1-PeF, whose critical current density (J_C) was 503 kA/cm² self-field at 10 K, and its crystal size was the smallest (0.24 µm) among all the tested samples, which is consistent with the theory that a smaller crystal size can improve the J_C of MgB₂. However, in high field, S2-PeF had the highest J_C value, which is related to the pinning mechanism and can be explained by grain boundary pinning (GBP). With an increase in preparation temperature, S2 showed a slightly stronger anisotropy of properties. In addition, with an increase in temperature, point pinning becomes stronger to form effective pinning centers, leading to a higher J_C.

High-Conductivity Chalcogenide Glasses in Ag-Ga2Te3-SnTe Systems and Their Suitability as Thermoelectric Materials

A novel high-conductivity Ag_x[(Ga₂Te₃)₃₄(SnTe)₆₆]_100-x tellurium-based glassy system was fabricated via melt spinning with the glass formation area in the range of x = 0-15 mol %. A bulk Ag₁₀[(Ga₂Te₃)₃₄(SnTe)₆₆]₉₀ glass (A10) was obtained via spark plasma sintering at 450 K using a 5 min dwell time and 400 MPa pressure. The fabricated A10 glass exhibited higher room-temperature conductivity (σ_300 K = 46 S m^-1), larger glass transition temperature (T_g = 482 K), and ultralower thermal conductivity (∼0.19 W m^-1 K^-1) compared to those of previously reported Cu-Ge-Te, Cu-As-Te, Cu-Ge-As-Te, and Cu-As-Se-Te glassy systems with the approximate doping concentrations of 5-20%, demonstrating that this distinctive Ag-Ga₂Te₃-SnTe system is interesting materials for thermoelectric applications. The high-conductivity Ag-Ga₂Te₃-SnTe glassy system will extend investigations into similar glassy semiconductors and also can be used for preparing glass ceramics with potential applications in other fields.

New Strategy for Preparation of Yttria Powders with Atypical Morphologies and Their Sintering Behavior

A modified precipitation method was used to prepare yttria powers for the fabrication of yttria ceramics in this study. The precipitation behavior, phase evolution, and shape of the yttria precursor were all examined in the presence or absence of an electric field. The findings demonstrate that the phases of the yttria precursor were Y₂(CO₃)₃·2H₂O with and without an electric field, while the morphology changed from flake to needle-like under the action of the electric field. After calcining both yttria precursors at 750 °C, yttria powders with similar morphologies were obtained and then densified via conventional sintering (CS) and spark plasma sintering (SPS). The densification and thermal shock resistance of the yttria ceramics were investigated. The yttria ceramics sintered using SPS had higher bulk density and thermal shock resistance than the samples sintered using CS. When the sintering process for the ceramics sintered from needle-like yttria powder was switched from CS to SPS, the bulk density increased from 4.44 g·cm^-3 to 5.01 g·cm^-3, while the number of thermal shock tests increased from two to six. The denser samples showed better thermal shock resistance, which may be related to the fracture mechanism shifting from intergranular fracture to transgranular fracture.

Large-Scale Colloidal Synthesis of Chalcogenides for Thermoelectric Applications

A simple and effective preparation of solution-processed chalcogenide thermoelectric materials is described. First, PbTe, PbSe, and SnSe were prepared by gram-scale colloidal synthesis relying on the reaction between metal acetates and diphenyl dichalcogenides in hexadecylamine solvent. The resultant phase-pure chalcogenides consist of highly crystalline and defect-free particles with distinct cubic-, tetrapod-, and rod-like morphologies. The powdered PbTe, PbSe, and SnSe products were subjected to densification by spark plasma sintering (SPS), affording dense pellets of the respective chalcogenides. Scanning electron microscopy shows that the SPS-derived pellets exhibit fine nano-/micro-structures dictated by the original morphology of the key constituting particles, while the powder X-ray diffraction and electron microscopy analyses confirm that the SPS-derived pellets are phase-pure materials, preserving the structure of the colloidal synthesis products. The resultant solution-processed PbTe, PbSe, and SnSe exhibit low thermal conductivity, which might be due to the enhanced phonon scattering developed over fine microstructures. For undoped n-type PbTe and p-type SnSe samples, an expected moderate thermoelectric performance is achieved. In contrast, an outstanding figure-of-merit of 0.73 at 673 K was achieved for undoped n-type PbSe outperforming, the majority of the optimized PbSe-based thermoelectric materials. Overall, our findings facilitate the design of efficient solution-processed chalcogenide thermoelectrics.

Nanoindentation and Structural Analysis of Sintered TiAl(100-x)-xTaN Composites at Room Temperature

The nanohardness, elastic modulus, anti-wear, and deformability characteristics of TiAl_(100-x)-_xTaN composites containing 0, 2, 4, 6, 8, and 10 wt.% of TaN were investigated via nanoindentation technique in the present study. The TiAl_(100-x)-_xTaN composites were successfully fabricated via the spark plasma sintering technique (SPS). The microstructure and phase formation of the TiAl sample constitute a duplex structure of γ and lamellar colonies, and TiAl₂, α-Ti, and TiAl phases, respectively. The addition of TaN results in a complex phase formation and pseudo duplex structure. The depth-sensing indentation evaluation of properties was carried out at an ambient temperature through a Berkovich indenter at a prescribed load of 100 mN and a holding time of 10 s. The nanoindentation result showed that the nanohardness and elastic modulus characteristics increased as the TaN addition increased but exhibited a slight drop when the reinforcement was beyond 8 wt.%. At increasing TaN addition, the yield strain (HEr), yield pressure (H3Er2), and elastic recovery index (WeWt) increased, while the plasticity index (WpWt) and the ratio of plastic and elastic work (RPE) reduced. The best mechanical properties were attained at the 8 wt.%TaN addition.

Microstructure and Mechanical Properties of Spark Plasma Sintered CoCrFeNiNbX High-Entropy Alloys with Si Addition

Three mechanically alloyed (MA) and spark plasma sintered (SPS) CoCrFeNiNbX (X = 5, 20, and 35 at.%) alloys with an addition of 5 at.% of SiC were investigated. The face-centered cubic (FCC) high-entropy solid solution, NbC carbides, and hexagonal Laves phase already developed during MA. In addition, the SPS compacting led to the formation of oxide particles in all alloys, and the Cr₇C₃ carbides in the Nb5 alloy. The fraction of the FCC solid solution decreased with increasing Nb concentration at the expense of the NbC carbide and the Laves phase. Long-term annealing at 800 °C led to the disappearance of the Cr₇C₃ carbide in the Nb5 alloy, and new oxides-Ni₆Nb₆O, Cr₂O₃, and CrNbO₄-were formed. At laboratory temperature, the Nb5 alloy, containing only the FCC matrix and carbide particles, was relatively strong and very ductile. At a higher Nb content (Nb20 and Nb35), the alloys became brittle. After annealing for 100 h at 800 °C, the Nb5 alloy conserved its plasticity and the Nb20 and Nb35 alloys maintained or even increased their brittleness. When tested at 800 °C, the Nb5 and Nb20 alloys deformed almost identically (CYS ~450 MPa, UTS ~500 MPa, plasticity ~18%), whereas the Nb35 alloy was much stronger (CYS of 1695 MPa, UCS of 1817 MPa) and preserved comparable plasticity.

Microstructure and Properties of NiCoCrAlTi High Entropy Alloy Prepared Using MA-SPS Technique

In this study, Ni₃₅Co₃₅Cr_12.6Al_7.5Ti₅Mo_1.68W_1.39Nb_0.95Ta_0.47 high entropy alloy (HEA) was prepared using mechanical alloying (MA) and spark plasma sintering (SPS) based on the unique design concept of HEAs and third-generation powder superalloys. The HEA phase formation rules of the alloy system were predicted but need to be verified empirically. The microstructure and phase structure of the HEA powder were investigated at different milling times and speeds, with different process control agents, and with an HEA block sintered at different temperatures. The milling time and speed do not affect the alloying process of the powder and increasing the milling speed reduces the powder particle size. After 50 h of milling with ethanol as PCA, the powder has a dual-phase FCC+BCC structure, and stearic acid as PCA inhibits the powder alloying. When the SPS temperature reaches 950 °C, the HEA transitions from a dual-phase to a single FCC phase structure and, with increasing temperature, the mechanical properties of the alloy gradually improve. When the temperature reaches 1150 °C, the HEA has a density of 7.92 g cm^-3, a relative density of 98.7%, and a hardness of 1050 HV. The fracture mechanism is one with a typical cleavage, a brittle fracture with a maximum compressive strength of 2363 MPa and no yield point.

Characteristics of Mg-Based Sintered Alloy with Au Addition

The magnesium-based alloys produced by mechanical alloying (MA) are characterized by specific porosity, fine-grained structure, and isotropic properties. In addition, alloys containing magnesium, zinc, calcium, and the noble element gold are biocompatible, so they can be used for biomedical implants. The paper assesses selected mechanical properties and the structure of the Mg₆₃Zn₃₀Ca₄Au₃ as a potential biodegradable biomaterial. The alloy was produced by mechanical synthesis with a milling time of 13 h, and sintered via spark-plasma sintering (SPS) carried out at a temperature of 350 °C and a compaction pressure of 50 MPa, with a holding time of 4 min and a heating rate of 50 °C∙min^-1 to 300 °C and 25 °C∙min^-1 from 300 to 350 °C. The article presents the results of the X-ray diffraction (XRD) method, density, scanning electron microscopy (SEM), particle size distributions, and Vickers microhardness and electrochemical properties via electrochemical impedance spectroscopy (EIS) and potentiodynamic immersion testing. The obtained results reveal the compressive strength of 216 MPa and Young's modulus of 2530 MPa. The structure comprises MgZn₂ and Mg₃Au phases formed during the mechanical synthesis, and Mg₇Zn₃ that has been formed during the sintering process. Although MgZn₂ and Mg₇Zn₃ improve the corrosion resistance of the Mg-based alloys, it has been revealed that the double layer formed because of contact with the Ringer's solution is not an effective barrier; hence, more data and optimization are necessary.

Recent Developments of High-Pressure Spark Plasma Sintering: An Overview of Current Applications, Challenges and Future Directions

Spark plasma sintering (SPS), also called pulsed electric current sintering (PECS) or field-assisted sintering technique (FAST) is a technique for sintering powder under moderate uniaxial pressure (max. 0.15 GPa) and high temperature (up to 2500 °C). It has been widely used over the last few years as it can achieve full densification of ceramic or metal powders with lower sintering temperature and shorter processing time compared to conventional processes, opening up new possibilities for nanomaterials densification. More recently, new frontiers of opportunities are emerging by coupling SPS with high pressure (up to ~10 GPa). A vast exciting field of academic research is now using high-pressure SPS (HP-SPS) in order to play with various parameters of sintering, like grain growth, structural stability and chemical reactivity, allowing the full densification of metastable or hard-to-sinter materials. This review summarizes the various benefits of HP-SPS for the sintering of many classes of advanced functional materials. It presents the latest research findings on various HP-SPS technologies with particular emphasis on their associated metrologies and their main outstanding results obtained. Finally, in the last section, this review lists some perspectives regarding the current challenges and future directions in which the HP-SPS field may have great breakthroughs in the coming years.

(Na, Zr) and (Ca, Zr) Phosphate-Molybdates and Phosphate-Tungstates: I-Synthesis, Sintering and Characterization

Submicron-grade powders of Na_1-xZr₂(PO₄)_3-x(XO₄)_x compounds (hereafter referred to as NZP) and Ca_1-xZr₂(PO₄)_3-x(XO₄)_x compounds (hereafter, CZP), X = Mo, W (0 ≤ x ≤ 0.5) were obtained by sol-gel synthesis. The compounds obtained were studied by X-ray diffraction phase analysis and electron microscopy. An increase in the W or Mo contents was shown to result in an increase in the unit cell volume of the NZP and CZP crystal lattices and in a decrease in the coherent scattering region sizes. Thermal expansion behavior at high temperatures of synthesized NZP and CZP compounds has been investigated. The dependencies of the parameters a and c on the heating temperature, as well as the temperature dependence of the crystal lattice unit cell volume V in the range from the room temperature up to 800 °C, were obtained. The dependencies of the average thermal expansion coefficient (α_av) and of the volume coefficient (β) on the W and Mo contents in the compositions of NZP and CZP compounds were studied. Ceramics Na_1-xZr₂(PO₄)_3-x(XO₄)_x with relatively high density (more than 97.5%) were produced by spark plasma sintering (SPS). The increase in the W or Mo contents in the ceramics leads to an increase in the relative density of NZP and to a decrease of the optimum sintering temperature. The mean grain size in the NZP ceramics decreases with increasing W or Mo contents. The study of strength characteristics has revealed that the hardness of the NZP ceramics is greater than 5 GPa, and that the minimum fracture toughness factor was 1 MPa·m^1/2.

Dielectric Spectroscopy of Calcium Titanate Processed by Spark Plasma Sintering

Calcium titanate (CaTiO₃) powder was compacted by spark plasma sintering (SPS). The resulting products were subjected to the phase stability study and dielectric characterization. The change in temperature of SPS between 1100 °C and 1250 °C had a clear and straightforward effect on density, porosity, relative permittivity, loss tangent, and DC resistivity. Since the SPS itself introduces certain oxygen deficiency into Ti-perovskites, all samples were annealed after SPS. However, this post-processing did not mask the effects of the SPS regime. Optical reflectance measurements were completed to compare and quantify the sample coloration and support the dielectric results with corresponding optical band gap estimations. Subtle changes in the CaTiO₃ crystal lattice arrangement, completed between 1150 °C and 1250 °C and documented in the literature for conventionally sintered samples, could not be confirmed for SPS-prepared calcium titanate. The novelty of this research work is in producing very stable dielectric ceramics and an indication of the SPS processing parameters suitable for this. The best sample showed at 1 MHz frequency the combination of relative permittivity 370, loss tangent 0.008, and DC resistivity 3 × 10¹² Ωm.

(Na, Zr) and (Ca, Zr) Phosphate-Molybdates and Phosphate-Tungstates: II-Radiation Test and Hydrolytic Stability

This paper introduces the results of hydrolytic stability tests and radiation resistance tests of phosphate molybdates and phosphate tungstates Na_1-xZr₂(PO₄)_3-x(XO₄)_x, X = Mo, W (0 ≤ x ≤ 0.5). The ceramics characterized by relatively high density (more than 97.5%) were produced by spark plasma sintering (SPS) of submicron powders obtained by sol-gel synthesis. The study focused on hydrolytic resistance of the ceramics in static mode at room temperature. After 28 days of testing in distilled water, the normalized leaching rate was determined. It was found that the ceramics demonstrated high hydrolytic resistance in static mode: the normalized leaching rates for Mo- and W-containing ceramics were 31·10^-6 and 3.36·10^-6 g·cm^-2·day^-1, respectively. The ceramics demonstrated high resistance to irradiation with 167 MeV Xe⁺²⁶ multiple-charged ions at fluences ranging from 1·10¹² to 6·10¹³ cm^-2. The Mo-containing Na_0.5Zr₂(PO₄)_2.5(XO₄)_0.5 ceramics were shown to have higher radiation resistance than phosphate tungstates. Radiation was shown to trigger an increase in leaching rates for W and Mo in the crystal structure of NZP ceramics.