Towards homogeneous spark plasma sintering of complex-shaped ceramic matrix composites

Research laboratories worldwide use the spark plasma sintering (SPS) technique for sintering metallic and ceramic matrix composites. Typically, the SPS sintered parts are low circular cylinders (discs). The upscaling and industrialization of SPS technology face two challenges: the limitation of shaping non-cylindrical parts and the inhomogeneous sintering of large-sized products. This paper addresses these challenges in sintering axisymmetric shells within an SPS setup with improved thermal insulation. The paper considers the sintering of a 75mm shell as a case study. The shell material is a zirconia-nanotube composite. Finite element analysis revealed that homogeneous sintering of such a shell requires careful thermal insulation of the entire setup. Investigation of phases, microstructure, density, microhardness, and fracture toughness in the sintered shell showed a homogeneous structure and uniform properties.