Liquid phase sintering (LPS) is a process for forming high performance, multiple-phase components from powders. It involves sintering under conditions where solid grains coexist with a wetting liquid. Many variants of LPS are applied to a wide range of engineering materials. Example applications for this technology are found in automobile engine connecting rods and high-speed metal cutting inserts. Scientific advances in understanding LPS began in the 1950s. The resulting quantitative process models are now embedded in computer simulations to enable predictions of the sintered component dimensions, microstructure, and properties. However, there are remaining areas in need of research attention. This LPS review, based on over 2,500 publications, outlines what happens when mixed powders are heated to the LPS temperature, with a focus on the densification and microstructure evolution events.

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Review: liquid phase sintering

Sintering occurs when packed particles are heated to a temperature where there is sufficient atomic motion to grow bonds between the particles The conditions that induce sintering depend on the material, its melting temperature, particle size, and a host of processing variables It is common for sintering to produce a dimensional change, typically shrinkage, where the powder compact densifies, leading to significant strengthening Microstructure coarsening is inherent to sintering, most evident as grain growth, but it is common for pore growth to occur as density increases During coarsening, the grain structure converges to a self-similar character seen in both the grain shape distribution and grain size distribution Coarsening behavior during sintering conforms to classic grain growth kinetics, modified to reflect the evolving microstructure These modifications involve the grain boundary coverage due to pores, liquid films, or second phases and the altered grain boundary mobility due to these phases

Coarsening in Sintering: Grain Shape Distribution, Grain Size Distribution, and Grain Growth Kinetics in Solid-Pore Systems

Processing strategy for consolidating tungsten heavy alloys for ordnance applications

A model is derived for the sintering densification of prealloyed particles that form internal liquids when heated over the solidus temperature. The model considers the powder size, composition, and microstructure, as well as the processing conditions of green density, heating rate, maximum temperature, hold time, and atmosphere. Internal liquid forms and spreads to create an interparticle capillary bond that induces densification during sintering. Densification is delayed until the particles achieve a mushy state due to grain boundary wetting by the internal liquid. This loss of rigidity and concomitant densification of the semisolid particles depends on the grain size and liquid quantity. Viscous flow is the assumed densification mechanism, where both viscosity and yield strength vary with the liquid content and particle microstructure. Densification predictions are compared to experimental data, giving agreement with previously reported rapid changes in sintered density over narrow temperature ranges. The model is tested using data from steels and tool steels of varying carbon contents, as well as boron-doped stainless steel, bronze, and two nickel-based alloys.

Supersolidus liquid-phase sintering of prealloyed powders

Controlled processing of heavy alloys containing 88 to 97 pct W resulted in high sintered densities and excellent bonding between the tungsten grains and matrix. For these alloys, deformation and fracture behavior were studiedvia slow strain rate tensile testing at room temperature. The flow stress increased and the fracture strain decreased with increasing tungsten content. The tradeoff between strength and ductility resulted in a maximum in the ultimate tensile strength at 93 pct W. Microstructure variations, notably grain size, explain sintering temperature and time effects on the properties. During tensile testing, cracks formed on the surface of the specimens at tungsten-tungsten grain boundaries. The crack density increased with plastic strain and tungsten content. The surface cracks, though initially blunted by the matrix, eventually increased in density until catastrophic failure occurred. An empirical failure criterion was developed relating fracture to a critical value of the surface crack tip separation distance. Application of the model explains the effects of microstructural variables on tensile properties.

Microstructure effects on tensile properties of tungsten-Nickel-Iron composites

Residual porosity has a strong negative effect on the ductility of tungsten-nickel-iron heavy metals. This investigation examines the sintering atmosphere role in stabilizing detrimental residual pore structures. Two types of experiments are reported on alloys containing 93, 95, or 97 wt pct W with Ni:Fe ratios of 7:3. The negative effect of prolonged sintering is attributed to pore coarsening involving trapped gas in the pores. Calculated pore growth rates for hydrogen filled pores suggest that pore coarsening involves both ripening and coalescence driven by tungsten grain growth. The effect of the sintering atmosphere is analyzed for final stage pore elimination. It is demonstrated that a change in sintering atmosphere from hydrogen to argon midway through the sintering cycle can aid pore degassing and increase the sintered ductility and strength.

K. S. Churn

Papers

Sintering Atmosphere Effects on the Ductility of W- Ni- Fe Heavy Metals