Abstract
We report on an ultrarapid (6 s) consolidation of binder-less WC using a novel Ultrahigh temperature Flash Sintering (UFS) approach. The UFS technique bridges the gap between electric resistance sintering (MUCH LESS-THAN1 s) and flash spark plasma sintering (20-60 s).
Compared to the well-established spark plasma sintering, the proposed approach results in improved energy efficiency with massive energy and time savings while maintaining a comparable relative density (94.6%) and Vickers hardness of 2124 HV. The novelty of this work relies on (i) multiple steps current discharge profile to suit the rapid change of electrical conductivity experienced by the sintering powder, (ii) upgraded low thermal inertia CFC dies and (iii) ultra-high consolidation temperature approaching 2750 degrees C.
Compared to SPS process, the UFS process is highly energy efficient (approximate to 200 times faster and it consumes approximate to 95% less energy) and it holds the promise of energy efficient and ultrafast consolidation of several conductive refractory compounds.