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Trends in Spark Plasma Sintering of Advanced Materials
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Trends in Spark Plasma Sintering of Advanced Materials

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Plasma Coatings, Surfaces & Interfaces".

Deadline for manuscript submissions: 10 August 2025 | Viewed by 12876

Special Issue Editors

Prof. Dr. Marcello Filgueira

E-Mail Website
Guest Editor
Advanced Materials Lab, Universidade Estadual do Norte Fluminense, Campos dos Goitacazes, Rio de Janeiro, Brazil
Interests: SPS; HPHT; hardmetals; diamonds; cBN; advanced ceramics; metal binders; biomaterials; characterizations; wear
Dr. Izabel Fernanda Machado

E-Mail Website
Guest Editor
Mechatronics and Mechanical System Engineering Department, Universidade de São Paulo, Sao Paulo, Brazil
Interests: development of advanced materials for cutting tools; hard materials processed by spark plasma sintering (SPS), including (but not limited to) modified hardmetals, novel binders for hard materials; SPS processed functional multi-graded materials (FGMs)
Special Issues, Collections and Topics in MDPI journals
Dr. Oleg Shichalin

E-Mail Website1 Website2
Guest Editor
Institute of High Technologies and Advanced Materials, Far Eastern Federal University, 8, Sukhanova St., 690091 Vladivostok, Russia
Interests: SPS technology; ceramic welding; ultra high temperature ceramics; biological porous materials; nuclear waste storage ceramics
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

As is well known worldwide, the spark plasma sintering (SPS) technique is one of the most advanced processing routes to obtain dense sintered bodies with improved general properties. The heating rate is rapid, but the sintering duration is short, enabling to achieve well-processed parts with high quality within good tolerances, thus meeting the Industry 4.0 requirements. SPS is the most cost-effective technique among all sintering routes. It has been used to process all kinds of metals, ceramics, and composite materials, even hard-to-sinter materials, such as strongly covalent ceramics, due to the generated plasma that originates among particles, due to the electromagnetic field which generates several current pulses in just a few milliseconds. 

We are pleased to invite you to contribute to this Special Issue, and we very much appreciate receiving contributions from your group and colleagues who use SPS to process advanced materials. We kindly ask you to encourage other colleagues to participate in this very important topic of research.

The aim of this Special Issue is to publish original and cutting-edge papers—research articles and reviews—on the trends of use of the SPS technique and its impact on industry and science, focusing on the application of the SPS technique to consolidate advanced materials. Contributions on the state of the art of the SPS technique are welcome, as are broad discussions around critical points such as the clear definition of plasma generation. We will additionally focus on SPS-processed advanced materials, such as designed metal alloys, coated materials, functional gradient materials (FGMs), and ceramics and composites for several applications. Studies on interfacial reactions that occur during SPS treatment, especially considering surface and/or coatings, are encouraged. Characterizations of SPS-processed advanced materials are of interest, particularly with a focus on surface and interface phenomena.

We look forward to receiving your contributions.

Prof. Dr. Marcello Filgueira
Dr. Izabel Fernanda Machado
Dr. Oleg Shichalin
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • SPS
  • advanced materials
  • SPS advances
  • SPS trends
  • surface modifications
  • interfacial phenomena

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Published Papers (8 papers)

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Research

15 pages, 5913 KiB  
Article
In Situ Fabrication of Ti-xNb Alloys by Conventional Powder Metallurgy
by Rogelio Macias, Jr., Pedro Garnica González, Luis Olmos, Ivon Alanis-Fuerte, Omar Jimenez, Francisco Alvarado-Hernández, Melina Velasco-Plascencia and Jorge Alejandro Ávila-Olivera
Coatings 2024, 14(7), 897; https://doi.org/10.3390/coatings14070897 - 18 Jul 2024
Viewed by 921
Abstract
The present study shows the effect of Nb on a Ti matrix to fabricate composites via the conventional powder metallurgy for medical applications. Ti powder mixture compacts with different Nb contents were obtained from the conventional pressing and sintering technique. The sintering behavior [...] Read more.
The present study shows the effect of Nb on a Ti matrix to fabricate composites via the conventional powder metallurgy for medical applications. Ti powder mixture compacts with different Nb contents were obtained from the conventional pressing and sintering technique. The sintering behavior was evaluated using the dilatometry technique, and the microstructure was studied using scanning electron microscopy (SEM) and X-ray diffraction (XDR). The mechanical properties were obtained from simple compression tests, and the corrosion resistance was determined from a standard three-electrode arrangement in Hank’s solution. The results showed that the Nb in the Ti matrix limits the evolution of sintering depending on the Nb content. Nb slightly accelerates the phase transition temperature. The microstructure and X-rays revealed that biphasic α + β-Ti structures can be obtained, in addition to retaining the β-Ti phase and forming the martensitic phases α′ and α″ of Ti. Likewise, the mechanical behavior showed a Young’s modulus of 10–45 GPa, which is close to that reported for human bones. Furthermore, the circuit analysis revealed that the Ti-Nb sintered systems were conditioned by the surface oxide layer and that the oxide layer formed within the residual pores of the sintering process. Finally, it was demonstrated that adding Nb to the Ti matrix increases the corrosion resistance and that contents close to 15 wt.% of this element have the best results. Full article
(This article belongs to the Special Issue Trends in Spark Plasma Sintering of Advanced Materials)
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11 pages, 4131 KiB  
Article
Investigation of the Bonding Mechanism of Al Powder Particles through Pulse Current Sintering Technology
by Zhou Lv and Ruifeng Liu
Coatings 2024, 14(6), 759; https://doi.org/10.3390/coatings14060759 - 15 Jun 2024
Viewed by 812
Abstract
Compared with traditional powder metallurgy, pulse current sintering is an advanced powder-forming technology, but its bonding mechanism is still an open topic for debate. In this paper, pulse current sintering is used as the connection technology and millimeter-sized Al particles are used as [...] Read more.
Compared with traditional powder metallurgy, pulse current sintering is an advanced powder-forming technology, but its bonding mechanism is still an open topic for debate. In this paper, pulse current sintering is used as the connection technology and millimeter-sized Al particles are used as the research object. In the whole sintering process, no pressure was loaded; the function of the pulse current was the only source of heat with which to achieve the bonding of Al particles. The bonding mechanism of pulse current sintering was investigated from the perspective of material connection behavior. The results show that the pulse current density of the particle surface reaches 3.48 × 105 A/m2 instantly, while the current density of the particle center is only 8187 A/m2 at the initial stage, which is the main difference between pulse current sintering and traditional powder metallurgy sintering. With the densification process, the current density and temperature distribution in the contact region as well as the center of Al particles contact region tend to be more consistent. Finally, dense interfacial bonding was obtained, and the contact region of Al particles also demonstrated a high hardness value of 0.6385 GPa and yield strength value of 212.83 MPa. The whole process can be considered as a comprehensive action of melting (evaporation), diffusion, and plastic deformation. Based on the above results, a new technology, named high-frequency pulse current sintering, was proposed. Full article
(This article belongs to the Special Issue Trends in Spark Plasma Sintering of Advanced Materials)
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15 pages, 5763 KiB  
Article
Microstructural Evolution and Densification of Co-Based Alloy Powder by Spark Plasma Sintering for High-Hardness Applications
by Fernando Juárez-López, Rubén Cuamatzi-Meléndez, Ángel de Jesús Morales-Ramírez, Margarita García-Hernández and María Luz Carrera-Jota
Coatings 2024, 14(4), 479; https://doi.org/10.3390/coatings14040479 - 13 Apr 2024
Viewed by 799
Abstract
This work presents the densification of Co-based alloy powders by a spark plasma sintering process. The densification process was carried out at a temperature range of 800 °C to 1100 °C in order to obtain sintered coupons and study their microstructure and mechanical [...] Read more.
This work presents the densification of Co-based alloy powders by a spark plasma sintering process. The densification process was carried out at a temperature range of 800 °C to 1100 °C in order to obtain sintered coupons and study their microstructure and mechanical properties. The shrinkage behaviour of the sintered coupons was studied, and an optimal densification temperature was defined. The microstructural analysis showed a reduction in porosity with temperature increment along with the development of a fine microstructure comprised of cobalt-molybdenum-chromium-silicon-based intermetallic laves phases, which are dispersed in a softer cobalt-based alloy matrix. X-diffraction analysis showed that these crystalline phases were well-dispersed, with a lattice parameter corresponding to a hexagonal system. The obtained high Vickers hardness values were attributed to the preservation of a fine microstructure and to the precipitation of Co-Mo phases. Three-point bending tests were performed in order to identify the strain path concerning the densification of the sintered coupons. Full article
(This article belongs to the Special Issue Trends in Spark Plasma Sintering of Advanced Materials)
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13 pages, 9082 KiB  
Article
Effect of Spark Plasma Sintering Temperature on the Microstructure and Thermophysical Properties of High-Silicon–Aluminum Composites
by Zhaoyang Kong, Zhipeng Wang, Yingmin Li and Runxia Li
Coatings 2024, 14(3), 299; https://doi.org/10.3390/coatings14030299 - 29 Feb 2024
Viewed by 1200
Abstract
Spark plasma sintering is a process of rapid, low-temperature, and high-density sintering. Moreover, traditional sintering methods can solve the problems of large grain sizes and low densities. The sintering temperature plays a crucial role in influencing the physical properties of high-silicon–aluminum (Si-Al) composites. [...] Read more.
Spark plasma sintering is a process of rapid, low-temperature, and high-density sintering. Moreover, traditional sintering methods can solve the problems of large grain sizes and low densities. The sintering temperature plays a crucial role in influencing the physical properties of high-silicon–aluminum (Si-Al) composites. This work investigated the impact of temperature on the microstructure, interface, and physical properties of high-Si-Al composites by spark plasma sintering. The results demonstrate that when the powder was processed by ball milling at a sintering temperature of 565 °C, the material exhibited the densest microstructure with minimal pore formation. The average size of the silicon phase is the smallest. The material’s thermal conductivity is 134.6 W/m·K, the thermal expansion coefficient is 8.55 × 10−6 K−1, the Brinell hardness is 219 HBW, the density is 2.415 g/cm3, and the density reaches 97.75%. An appropriate sintering temperature facilitates particle rearrangement and dissolution–precipitation processes, enhancing the material structure and performance. Full article
(This article belongs to the Special Issue Trends in Spark Plasma Sintering of Advanced Materials)
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18 pages, 10461 KiB  
Article
Nonuniform Distribution of Crystalline Phases and Grain Sizes in the Surface Layers of WC Ceramics Produced by Spark Plasma Sintering
by Ksenia E. Smetanina, Pavel V. Andreev, Evgeny A. Lantsev, Aleksey V. Nokhrin, Artem A. Murashov, Natalia V. Isaeva, Yury V. Blagoveshchensky, Maksim S. Boldin and Vladimir N. Chuvil’deev
Coatings 2023, 13(6), 1051; https://doi.org/10.3390/coatings13061051 - 6 Jun 2023
Cited by 1 | Viewed by 1422
Abstract
The research results conducted on binderless tungsten carbide (WC) ceramics obtained by spark plasma sintering (SPS) of WC powders with different average particle sizes (95, 800, 3000 nm) are presented. Nonuniform distribution of crystalline phases and microstructure of the WC ceramics was studied [...] Read more.
The research results conducted on binderless tungsten carbide (WC) ceramics obtained by spark plasma sintering (SPS) of WC powders with different average particle sizes (95, 800, 3000 nm) are presented. Nonuniform distribution of crystalline phases and microstructure of the WC ceramics was studied using layer-by-layer X-ray diffraction (XRD) analysis and scanning electron microscopy (SEM). Surface layers of the WC-based ceramics are characterized by nonuniform distribution of W2C crystalline phase and grain sizes, including the appearance of abnormally large grains. Thickness of the nonuniform layer was at least 50 μm. The effect under study is associated with an intense carbon diffusion from graphite foil. On the one hand, this contributed to a decrease in the intensity of W2C phase particle formation, which is transformed into α-WC phase due to the carbon. On the other hand, it caused abnormal grain growth in the layer where the carbon diffused. The obtained value of the carbon diffusion depth (50 μm) exceeds the values known from the literature (up to 1 μm in the case of volume diffusion even at temperature of 2370 °C and exposure time of ~60 h). The use of boron nitride (BN) as a protective coating on graphite mold parts did not prevent the formation of nonuniform layer on the ceramic surface. Full article
(This article belongs to the Special Issue Trends in Spark Plasma Sintering of Advanced Materials)
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16 pages, 7074 KiB  
Article
Spark Plasma Sintering of Si3N4 Ceramics with Y2O3–Al2O3 (3%–10% wt.) as Sintering Additive
by Pavel Andreev, Pavel Drozhilkin, Lyudmila Alekseeva, Ksenia Smetanina, Elena Rostokina, Stanislav Balabanov, Maksim Boldin, Artem Murashov and Gleb Shcherbak
Coatings 2023, 13(2), 240; https://doi.org/10.3390/coatings13020240 - 19 Jan 2023
Cited by 8 | Viewed by 2382
Abstract
The ceramic samples fabricated by spark plasma sintering of powder mixtures based on silicon nitride (Si3N4) were investigated. The powder mixtures were made by wet chemical methods from commercial α-Si3N4 powder (the particle size <5 μm) [...] Read more.
The ceramic samples fabricated by spark plasma sintering of powder mixtures based on silicon nitride (Si3N4) were investigated. The powder mixtures were made by wet chemical methods from commercial α-Si3N4 powder (the particle size <5 μm) and Y2O3-Al2O3 sintering additive (3% to 10% wt.). Sintering was carried out at the heating rate of 50 °C/min and the load of 70 MPa until the shrinkage end. The powder mixtures and ceramic samples were characterized by scanning electron microscopy and X-ray diffraction. The shrinkage of the powder mixtures during sintering was analyzed, and the activation energy of sintering was calculated according to the Young-Cutler model. The density, microhardness, and fracture toughness of the ceramic samples were also measured. All samples had high relative densities (98%–99%), Vickers microhardness 15.5–17.4 GPa, and Palmquist fracture toughness, 3.8–5.1 MPa∙m1/2. An increase in the amount of sintering additive led to a decrease in the shrinkage temperature of the powder mixtures. The amount of β-Si3N4 in the ceramics decreased monotonically with the increasing amount of sintering additive. The shrinkage rate did not decrease to zero when the maximum compaction was reached at 3% wt. of the sintering additive. On the contrary, it increased sharply due to the beginning of the Si3N4 decomposition. Full article
(This article belongs to the Special Issue Trends in Spark Plasma Sintering of Advanced Materials)
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10 pages, 3179 KiB  
Article
Functionally Gradient Material Fabrication Based on Cr, Ti, Fe, Ni, Co, Cu Metal Layers via Spark Plasma Sintering
by Oleg O. Shichalin, Evgeniy K. Papynov, Igor Yu. Buravlev, Anastasiya A. Buravleva, Sergey V. Chuklinov, Ekaterina A. Gridasova, Anton V. Pogodaev, Valreiia A. Nepomnyushchaya, Zlata E. Kornakova, Alexey O. Lembikov, Danila V. Gritsuk, Olesya V. Kapustina, Sofia S. Gribanova and Yun Shi
Coatings 2023, 13(1), 138; https://doi.org/10.3390/coatings13010138 - 10 Jan 2023
Cited by 5 | Viewed by 2717
Abstract
The paper presents a method of obtaining functionally graded material (FGM) of heterogeneous (layered) type based on joined metals Cr-Ti-Fe-Co-Ni-Cu using spark plasma sintering (SPS) technology. The structure, elemental and phase composition of FGM obtained on the basis of joined metals with different [...] Read more.
The paper presents a method of obtaining functionally graded material (FGM) of heterogeneous (layered) type based on joined metals Cr-Ti-Fe-Co-Ni-Cu using spark plasma sintering (SPS) technology. The structure, elemental and phase composition of FGM obtained on the basis of joined metals with different values of the temperature coefficient of linear expansion (CTLE) were studied by SEM, EDS and XRD methods with regard to the phase states of the alloy system. Based on the Vickers microhardness data, the evaluation of the mechanical characteristics of FGM in the whole sample body and locally at the contact boundaries of the joined metals was carried out. The results of the study are new and represent a potential for FGM, as well as functionally graded coatings (FGC), which have special physical, chemical and mechanical properties and are highly demanded for the manufacture of structures and products for industrial applications. Full article
(This article belongs to the Special Issue Trends in Spark Plasma Sintering of Advanced Materials)
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15 pages, 6505 KiB  
Article
Experimental Study to Assess Fracture Toughness in SPS Sintered WC–10% Co Hardmetal by Modifying the Palmqvist Test
by Daniel Willemam Trindade, Renan da Silva Guimarães, Rafael Delorence Lugon, Elias Rocha Gonçalves Junior, Alessandra Agna Araújo dos Santos and Marcello Filgueira
Coatings 2022, 12(12), 1809; https://doi.org/10.3390/coatings12121809 - 24 Nov 2022
Cited by 4 | Viewed by 1594
Abstract
Hardmetals are widely used as cutting, machining, and drilling tools for rocks due to their excellent properties of hardness, fracture toughness, and wear resistance over a wide temperature range. This study proposed to evaluate the fracture toughness of WC–10% Co carbide, sintered via [...] Read more.
Hardmetals are widely used as cutting, machining, and drilling tools for rocks due to their excellent properties of hardness, fracture toughness, and wear resistance over a wide temperature range. This study proposed to evaluate the fracture toughness of WC–10% Co carbide, sintered via spark plasma sintering—SPS, through the Vickers indentation measures, using a modification of the Palmqvist test, which is widely used to assess the toughness of cemented carbides, and to compare this result with the results of six different conventional models: Shetty, Niihara, Laugier, ISO 28079, Hanyaloglu, and Lankford. The model to assess the toughness proposed in this study showed similarity with the Palmqvist test. However, there were considerable differences in the KIC values for the different models, such as 13.36 MPa·m1/2 and 4.44 MPa·m1/2 for the same application load. Comparing the values of the conventional fracture toughness and proposed fracture toughness, the greatest difference between the fracture toughness values was found in the Lankford equation, which varied by 14.74%. The Hanyaloglu equation showed a smaller difference between the fracture toughness values, with a greater variation of 3.61% and lower variation of 1.54%. Adequate results of hardness were obtained, with a maximum of 20.93 ± 0.25 GPa, minimum of 15.76 ± 0.63 GPa, and densification of 99.14 ± 0.47 g/cm3. Full article
(This article belongs to the Special Issue Trends in Spark Plasma Sintering of Advanced Materials)
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