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

Transforming Nanocrystals into Superhard Boron Carbide Nanostructures

Boron carbide (B4+δC) possesses a large potential as a structural material owing to its lightness, refractory character, and outstanding mechanical properties. However, its large-scale industrialization is set back by its tendency to amorphize when subjected to an external stress. In the present work, we design a path toward nanostructured boron carbide with greatly enhanced hardness and resistance to amorphization. The reaction pathway consists of triggering an isomorphic transformation of covalent nanocrystals of Na1-xB5-xC1+x (x = 0.18) produced in molten salts. The resulting 10 nm B4.1C nanocrystals exhibit a 4-fold decrease of size compared to previous works. Solid-state 11B and 13C NMR coupled to density functional theory (DFT) reveal that the boron carbide nanocrystals are made of a complex mixture of atomic configurations, which are located at the covalent structural chains between B11C icosahedral building units. These nanocrystals are combined with a spark plasma-sintering-derived method operated at high pressure. This yields full densification while maintaining the particle size. The nanoscaled grains and high density of grain boundaries provide the resulting nanostructured bodies with significantly enhanced hardness and resistance to amorphization, thus delivering a superhard material.

Development of an Alternative Manufacturing Technology for Niobium Components

Due to their physical and mechanical properties, niobium products are used in the nuclear power industry, chemical industry, electronics, medicine and in the defence industry. Traditional manufacturing technology for these products is characterized by long production cycles and significant material losses during their surface machining. This paper presents the results of a study on the fabrication of niobium products by Spark Plasma Sintering (SPS). Structural and mechanical tests were conducted on the products obtained, as well as a comparative analysis with the properties of products obtained using traditional technology. Based on the analysis of the test results obtained, recommendations were made for the sintering of Nb powders. It was found that the optimum temperature for sintering the powder is 2000 °C as the density of the material obtained is close to the theoretical density. The microstructure obtained is comparable to samples obtained by the traditional method after recrystallization annealing. Samples obtained according to the new technology are characterized by higher mechanical properties Rp0.2 and Rm and the highest hardness.

Radiation Synthesis of High-Temperature Wide-Bandgap Ceramics

This paper presents the results of ceramic synthesis in the field of a powerful flux of high-energy electrons on powder mixtures. The synthesis is carried out via the direct exposure of the radiation flux to a mixture with high speed (up to 10 g/s) and efficiency without the use of any methods or means for stimulation. These synthesis qualities provide the opportunity to optimize compositions and conditions in a short time while maintaining the purity of the ceramics. The possibility of synthesizing ceramics from powders of metal oxides and fluorides (MgF2, BaF2, WO3, Ga2O3, Al2O3, Y2O3, ZrO2, MgO) and complex compounds from their stoichiometric mixtures (Y3Al3O12, Y3AlxGa(5-x) O12, MgAl2O4, ZnAl2O4, MgWO4, ZnWO4, BaxMg(2-x) F4), including activators, is demonstrated. The ceramics synthesized in the field of high-energy electron flux have a structure and luminescence properties similar to those obtained by other methods, such as thermal methods. The results of studying the processes of energy transfer of the electron beam mixture, quantitative assessments of the distribution of absorbed energy, and the dissipation of this energy are presented. The optimal conditions for beam treatment of the mixture during synthesis are determined. It is shown that the efficiency of radiation synthesis of ceramics depends on the particle dispersion of the initial powders. Powders with particle sizes of 1-10 µm, uniform for the synthesis of ceramics of complex compositions, are optimal. A hypothesis is put forward that ionization processes, resulting in the radiolysis of particles and the exchange of elements in the ion-electron plasma, dominate in the formation of new structural phases during radiation synthesis.

Testing for Abrasion Resistance of WC-Co Composites for Blades Used in Wood-Based Material Processing

Commonly used tool materials for machining wood-based materials are WC-Co carbides. Although they have been known for a long time, there is still much development in the field of sintered tool materials, especially WC-Co carbides and superhard materials. The use of new manufacturing methods (such as FAST-field-assisted sintering technology), which use pulses of electric current for heating, can improve the properties of the materials used for cutting tools, thereby increasing the cost-effectiveness of machining. The ability to increase tool life without the downtime associated with tool wear allows significant cost savings, particularly in mass production. This paper presents the results of a study of the effect of grain size and cobalt content of carbide tool sinters on the tribological properties of the materials studied. The powders used for consolidation were characterised by irregular shape and formed agglomerates of different sizes. Tribological tests were carried out using the T-01 (ball-on-disc) method. In order to determine the wear kinetics, the entire friction path was divided into 15 cycles of 200 m and the weight loss was measured after each stage. In order to determine the mechanism and intensity of wear of the tested materials under technically dry friction conditions, the surface of the tested sinters was observed before the test and after 5, 10, and 15 cycles. The conclusions of the study indicate that the predominant effect of surface cooperation at the friction node is abrasion due to the material chipping that occurs during the process. The results confirm the influence of sintered grain size and cobalt content on durability. In the context of the application of the materials in question for cutting tools, it can be pointed out that sintered WC(0.4)_4 has the highest potential for use in the manufacture of cutting tools.

The Optimization of Radiation Synthesis Modes for YAG:Ce Ceramics

Synthesis in the radiation field is a promising direction for the development of materials transformation processes, especially those differing in melting temperature. It has been established that the synthesis of yttrium-aluminum ceramics from yttrium oxides and aluminum metals in the region of a powerful high-energy electron flux is realized in 1 s, without any manifestations that facilitate synthesis, with high productivity. It is assumed that the high rate and efficiency of synthesis are due to processes that are realized with the formation of radicals, short-lived defects formed during the decay of electronic excitations. This article presents descriptions of the energy-transferring processes of an electron stream with energies of 1.4, 2.0, and 2.5 MeV to the initial radiation (mixture) for the production of YAG:Ce ceramics. YAG:Ce (Y₃Al₅O₁₂:Ce) ceramics samples in the field of electron flux of different energies and power densities were synthesized. The results of a study of the dependence of the morphology, crystal structure, and luminescence properties of the resulting ceramics on the synthesis modes, electron energy, and electron flux power are presented.