This review article aims to provide an updated and comprehensive description of the development of the Electric Current Activated/assisted Sintering technique (ECAS) for the obtainment of dense materials including nanostructured ones. The use of ECAS for pure sintering purposes, when starting from already synthesized powders promoters, and to obtain the desired material by simultaneously performing synthesis and consolidation in one-step is reviewed. Specifically, more than a thousand papers published on this subject during the past decades are taken into account. The experimental procedures, formation mechanisms, characteristics, and functionality of a wide spectrum of dense materials fabricated by ECAS are presented. The influence of the most important operating parameters (i.e. current intensity, temperature, processing time, etc.) on product characteristics and process dynamics is reviewed for a large family of materials including ceramics, intermetallics, metal–ceramic and ceramic–ceramic composites. In this review, systems where synthesis and densification stages occur simultaneously, i.e. a fully dense product is formed immediately after reaction completion, as well as those ones for which a satisfactory densification degree is reached only by maintaining the application of the electric current once the full reaction conversion is obtained, are identified. In addition, emphasis is given to the obtainment of nanostructured dense materials due to their rapid progress and wide applications. Specifically, the effect of mechanical activation by ball milling of starting powders on ECAS process dynamics and product characteristics (i.e. density and microstructure) is analysed. The emerging theme from the large majority of the reviewed investigations is the comparison of ECAS over conventional methods including pressureless sintering, hot pressing, and others. Theoretical analysis pertaining to such technique is also proposed following the last results obtained on this topic.

Consolidation/synthesis of materials by electric current activated/assisted sintering

http://liu.diva-portal.org/smash/get/diva2:303552/FULLTEXT01

The Mn+1AXn phases: Materials science and thin-film processing

Field-assisted sintering technology/Spark plasma sintering is a low voltage, direct current (DC) pulsed current activated, pressure-assisted sintering, and synthesis technique, which has been widely applied for materials processing in the recent years. After a description of its working principles and historical background, mechanical, thermal, electrical effects in FAST/SPS are presented along with the role of atmosphere. A selection of successful materials development including refractory materials, nanocrystalline functional ceramics, graded, and non-equilibrium materials is then discussed. Finally, technological aspects (advanced tool concepts, temperature measurement, finite element simulations) are covered.

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Field-Assisted Sintering Technology/Spark Plasma Sintering: Mechanisms, Materials, and Technology Developments

The MAX phases are a group of layered ternary compounds with the general formula Mn+1AXn (M: early transition metal; A: group A element; X: C and/or N; n = 1–3), which combine some properties of metals, such as good electrical and thermal conductivity, machinability, low hardness, thermal shock resistance and damage tolerance, with those of ceramics, such as high elastic moduli, high temperature strength, and oxidation and corrosion resistance. The publication of papers on the MAX phases has shown an almost exponential increase in the past decade. The existence of further MAX phases has been reported or proposed. In addition to surveying this activity, the synthesis of MAX phases in the forms of bulk, films and powders is reviewed, together with their physical, mechanical and corrosion/oxidation properties. Recent research and development has revealed potential for the practical application of the MAX phases (particularly using the pressureless sintering and physical vapour deposition coating rout...

Progress in research and development on MAX phases: a family of layered ternary compounds

The more than 60 ternary carbides and nitrides, with the general formula Mn+1AXn—where n = 1, 2, or 3; M is an early transition metal; A is an A-group element (a subset of groups 13–16); and X is C and/or N—represent a new class of layered solids, where Mn+1Xn layers are interleaved with pure A-group element layers. The growing interest in the Mn+1AXn phases lies in their unusual, and sometimes unique, set of properties that can be traced back to their layered nature and the fact that basal dislocations multiply and are mobile at room temperature. Because of their chemical and structural similarities, the MAX phases and their corresponding MX phases share many physical and chemical properties. In this paper we review our current understanding of the elastic and mechanical properties of bulk MAX phases where they differ significantly from their MX counterparts. Elastically the MAX phases are in general quite stiff and elastically isotropic. The MAX phases are relatively soft (2–8 GPa), are most readily machinable, and are damage tolerant. Some of them are also lightweight and resistant to thermal shock, oxidation, fatigue, and creep. In addition, they behave as nonlinear elastic solids, dissipating 25% of the mechanical energy during compressive cycling loading of up to 1 GPa at room temperature. At higher temperatures, they undergo a brittle-to-plastic transition, and their mechanical behavior is a strong function of deformation rate.

Elastic and Mechanical Properties of the MAX Phases

Synthesis and thermal and electrical properties of bulk Cr2AlC

ZrB 2 –20 vol%SiC ceramics without and with additive of 2 wt% carbon nanotubes (CNTs) were fabricated by hot-pressing at 1900 °C for 1 h under 30 MPa using ZrB 2 , SiC and CNTs as starting materials. The fracture toughness increased about 15%, but hardness, flexural strength as well as thermal conductivity did not vary significantly from the addition of CNTs.

Effect of carbon nanotubes on the properties of ZrB2–SiC ceramics

Dense and predominantly single-phase samples of Cr2AlC, together with a trace amount of Cr7C3, were fabricated by hot pressing of a mixture of chromium, aluminum, and graphite powders at 1400°C for 1 h. The hardness, Young's modulus, flexural strength, and compressive strength of Cr2AlC samples were 5.2, 288 GPa, 483±29, and 1159±23 MPa, respectively, which are comparable with those of Ti3AlC2 and Nb2AlC. The material exhibits good damage tolerance. For indentation loads up to 50 N, the post-indentation flexural strengths decrease by approximately 10% and by 31% for a load of 100 N. The flexural strengths of Cr2AlC samples quenched from 300°C to room temperature decrease from 483 to 455 MPa, while the retained strengths decrease quickly to 199 MPa when the quench temperature increases to 500°C. A further increase in quench temperature to 700°, 900°, and 1100°C results in a small reduction of strength.

Mechanical Properties of Cr2AlC Ceramics

The isothermal oxidation behavior of Cr2AlC ceramics oxidized in air at 1,100 and 1,250 °C for 20 h was studied. The phase compositions and microstructure of the oxidized surface were identified and observed by XRD and electron probe microanalysis (EMPA), respectively, while the cross sections of oxidized samples were also examined by EMPA equipped with energy dispersive spectrum capabilities. The results indicated that the oxidation of Cr2AlC samples was carried out by the outward diffusion of Al, together with small amounts of Cr, and the inward diffusion of O to form a surface layer of α-Al2O3, while carbides (Cr7C3 and Cr3C2), rather than oxides (Cr2O3), were formed in a layer under the surface. The mass gain per unit surface area of oxidized Cr2AlC followed a parabolic relation with oxidation time, and the parabolic rates, kp, for oxidation at 1,100 and 1,250 °C were 1.1 × 10−12 and 7.1 × 10−10 kg2 m4 s−1, respectively.

Wubian Tian

Papers

Synthesis and thermal and electrical properties of bulk Cr2AlC

Effect of carbon nanotubes on the properties of ZrB2–SiC ceramics

Mechanical Properties of Cr2AlC Ceramics

Oxidation behavior of Cr2AlC ceramics at 1,100 and 1,250 °C

Synthesis and characterization of Cr2AlC ceramics prepared by spark plasma sintering