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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

Sintered-reaction Bonded Silicon Nitride Densified by a Gas Pressure Sintering Process Effects of Rare Earth Oxide Sintering Additives

Reaction-bonded silicon nitrides containing rare-earth oxide sintering additives were densified by gas pressure sintering. The sintering behavior, microstructure and mechanical properties of the resultant specimens were analyzed. For that purpose, Lu2O3-SiO2 (US), La2O3-MgO (AM) and Y2O3-Al2O3 (YA) additive systems were selected. Among the tested compositions, densification of silicon nitride occurred at the lowest temperature when using the La2O3-MgO system. Since the Lu2O3-SiO2 system has the highest melting temperature, full densification could not be achieved after sintering at 1950oC. However, the system had a reasonably high bending strength of 527 MPa at 1200oC in air and a high fracture toughness of 9.2 MPa m1/2. The Y2O3-Al2O3 system had the highest room temperature bending strength of 1.2 GPa

36 MATERIALS SCIENCE↗
DOE OSTI2015

Microstructure characterization of Al–Cr–Fe quasicrystals sintered using spark plasma sintering

In this study, Al–Cr–Fe powders were consolidated using spark plasma sintering at different temperatures (650 °C, 700 °C, 750 °C and 800 °C). The sintered samples were investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX) and transmission electron microscopy (TEM). The porosity of the pellets is very sensitive to the sintering temperature: it reduces sharply from around 29.3% to around 3.1% when the sintering temperature increases from 650 °C to 700 °C probably due to the softening of quasicrystals at elevated temperatures. Metastable icosahedral Al–Cr–Fe transforms to stable decagonal Al–Cr–Fe in sintering process. Stable icosahedral Al–Cr–Fe forms in the samples sintered at 700 °C, 750 °C and 800 °C. Both stable quasicrystalline phases form through the nucleation and growth process in the sintering process. Selected area electron diffraction (SAED) analysis shows that the icosahedral phase and the decagonal phase formed in the sintering process have a quasilattice constant of about 0.45 nm and 1.2 nm, respectively. - Highlights: • Al–Cr–Fe quasicrystals were sintered using spark plasma sintering. • Metastable icosahedral Al–Cr–Fe transforms to decagonal Al–Cr–Fe during sintering. • Stable icosahedral Al–Cr–Fe forms during sintering at 700 °C to 800 °C. • Strain softening of quasicrystals at high temperature promotes SPS sintering.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Moderate temperature sintering of BaZr 0.8 Y 0.2 O 3-δ protonic ceramics by A novel cold sintering pretreatment

The state-of-the-art protonic ceramic conductor BaZr 0.8 Y 0.2 O 3-δ (BZY20) requires an extremely high sintering temperature (≥1700 °C) to achieve the desired relative density and microstructure necessary to function as a proton conducting electrolyte. In this work, we developed a cold sintering pretreatment assisted moderate-temperature sintering method for the fabrication of high-quality pure BZY20 pellets. BZY20 pellets with high relative density of ~94% were fabricated with a final sintering temperature of 1500 °C (200 °C lower than the traditional sintering temperature). A comparison with BZY20 control samples indicated that the proper amount of BaCO 3 introduced on the BZY20 particle surface and the high green density achieved by cold sintering pretreatment were the main drivers for lowering the sintering temperature. The electrical conductivity measurement by electrochemical impedance spectroscopy showed that the as-prepared BZY20 pellets have a proton conductivity comparable to the state-of-the-art values. The cold sintering pretreatment outlined in this work has the potential to lower the sintering temperatures for similar types of protonic ceramic materials under consideration for a wide range of energy conversion and storage applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Microstructure refinement of hot deformed Dy-free NdFeB magnets through a novel cold sintering approach by pressure-assisted spark plasma sintering

Anisotropic fine-grained Dy-free NdFeB high-performance magnets were produced using a novel cold sintering approach by pressure-assisted spark plasma sintering (SPS). The NdFeB nanocrystalline ribbon powders were subjected to cold sintering below 450 °C using pressure-assisted SPS, followed by hot deformation at 710 °C and 810 °C via SPS. Results indicate that cold sintering below 450 °C effectively restricts grain growth in the NdFeB magnets, yielding sub-100 nm scale grains across both fine-grained regions and most coarse-grained regions. The refined grain structure achieved through cold sintering allows for a lower hot deformation temperature as compared with the magnet by conventional sintering, as finer grains allow easier deformation and grain sliding/rotation. This process produces a highly fine-grained and anisotropic microstructure to achieve high magnetic performance (i.e., high intrinsic coercivity, remanence, and maximum energy product) in the magnets. The cold sintering (at 350 °C) and lower hot deformation temperatures required (e.g., 710 °C) help control grain coarsening and limit grain size that is commensurate with the size of a single magnetic domain of the Nd 2 Fe 14 B magnetic matrix phase, resulting in high intrinsic coercivity (H ci =11.4 kOe). Furthermore, the reduced hot deformation temperature mitigates the formation of coarse grain bands, leading to improved magnetic properties, specifically an increased remanence (B r = 14.3 kGs) and a high maximum energy product ((BH) max = 48 MGOe). In conclusion, cold sintered hot deformed NdFeB magnet also shows good thermal stability with reversible temperature coefficient α(B r )= -0.097 %/K and α(H ci )= -0.616 %/K at elevated temperatures up to 400 K.

Cold Sintering↗
DOE OSTI2018

Effect of sintering temperature on structural, magnetic and electrical transport properties of La0.67Ca0.33MnO3 ceramics prepared by Plasma Activated Sintering

Highlights: • La{sub 0.67}Ca{sub 0.33}MnO{sub 3} were prepared by using Plasma Activated Sintering technology. • Detailed studies of sintering temperature effect on structural, magnetic and electrical transport behaviors were investigated. • The observed behaviors have been explained by oxygen vacancy effect in combination with grain size effect. - Abstract: La{sub 0.67}Ca{sub 0.33}MnO{sub 3} (LCMO) ceramics were prepared by Plasma Activated Sintering (PAS). The effect of sintering temperature on structural, magnetic and electrical transport properties of the LCMO ceramics were investigated. XRD and SEM characterizations of the LCMO ceramics indicated that all samples exhibited single orthorhombic phase. Also, through PAS dense LCMO ceramics were obtained. Certain interesting phenomena were observed from the PAS sintering temperature effect on the magnetic and transport behaviors of LCMO ceramics, which were significantly different from traditional sintering methods The magnetization decreased and the resistivity increased as the sintering temperature increased, whereas the T{sub C} and T{sub IM} shifted towards the lower temperature side. The conduction mechanism of all samples was electron-magnon scattering process in the ferromagnetic low-temperature region, while the paramagnetic high-temperature region mechanism was explained with the variable range hopping (VRH) model. All these behaviors were explained through the oxygen vacancy effect in combination with the grain size effect.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Comparing hydrothermal sintering and cold sintering process: Mechanisms, microstructure, kinetics and chemistry

In this study, we report the sintering of zinc oxide (ZnO) through the comparison between the hydrothermal sintering (HS) and the cold sintering process (CSP) operating in closed and open conditions, respectively. Sintering was performed at 155 ± 5 °C applying a pressure of 320 MPa, and during different holding times (0 min, 20 min, 40 min and 80 min). Whatever the low sintering process used, ceramics characteristics are almost similar in terms of relative densities and ZnO structure. However, several differences such as the nature of stabilized phases, grain sizes and quantities of residual molecules in the densified pellets, were characterized and explained. The formation of zinc acetate “bridges” was observed ex situ in hydrothermally sintered samples. Lastly, a detailed ReaxFF molecular dynamics simulation was performed to help understand the formation mechanisms of zinc acetate “bridges” and compare the chemical activities between HS and CSP.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Microstructure characterization of electric field assisted sintering (EFAS) sintered metallic and ceramic materials using local thermal diffusivity measurement

Electric Field Assisted Sintering (EFAS, also referred to as spark plasma sintering) is a powerful technology for the consolidation of powder materials. The high heating rate during the sintering process is critical for minimizing energy consumption, but it can also cause microstructure heterogeneities in sintered parts, such as spatially varied porosity. The examination of localized porosity usually requires the use of a scanning electron microscope with a carefully prepared surface. In this paper, photothermal radiometry is used to measure local thermal diffusivity and extract localized porosity of EFAS-sintered parts by using a percolation-threshold model. Applying this approach, we identified the radial position-dependent porosity variation in EFAS parts, which is likely formed due to the large temperature gradient during the sintering process. This approach has a unique advantage because it can measure samples with minimal or no surface preparation, enabling the possibility of in situ characterization in EFAS with proper system modification. Necessary modifications on the measurement approach for EFAS deployment and in situ characterization are also discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2014

A comparative study of conventionally sintered and microwave sintered nickel zinc ferrite

For the present work, nickel zinc ferrite having compositional formula Ni{sub 0.8}Zn{sub 0.2}Fe{sub 2}O{sub 4} was synthesized by conventional solid state method and sintered in conventional and microwave furnaces. Pellets were sintered with very short soaking time of 10 min at 1150 °C in microwave furnace whereas 4 hrs of soaking time was selected for conventional sintering at 1200 °C. Phase formation was confirmed by X-ray diffraction analysis technique. Scanning electron micrographs were taken for microstructural study. Dielectric properties were studied as a function of temperature. To study magnetic behavior, M-H hysteresis loops were recorded for both samples. It is observed that microwave sintered sample could obtain comparable properties to the conventionally sintered one in lesser soaking time at lower sintering temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Fabrication of large sintered pellets of Sb-doped n-type Mg{sub 2}Si using a plasma activated sintering method

Sb is known to be the most stable n-type dopant in Mg{sub 2}Si, whereas the reproducibility and sintering scalability of Sb-doped Mg{sub 2}Si has proved to be difficult. We have developed a metallic binder for the Sb-doped Mg{sub 2}Si sintering process. A remarkable benefit of the binder is that it enables us to reproducibly fabricate large sintered Sb-doped Mg{sub 2}Si pellets up to 30 mm in diameter with no internal cracks. For binder contents of 3-7 wt%, the observed power factor and thermal conductivity were identical to that of conventional Sb-doped samples, while excess binder degraded the TE properties. The binder mixture also plays a part in increasing the yield in the production of TE legs, up to 82% for 5 wt% Ni incorporation, as well as improving the hardness of the sintered sample. Incorporation of 5 wt% Ni binder affected an increase in the ZT value up to 0.97. - Graphical abstract: The sample of 30 mm in diameter is fabricated by using a Ni binder. Highlights: Black-Right-Pointing-Pointer We have developed a metallic binder for the Sb-doped Mg{sub 2}Si sintering process. Black-Right-Pointing-Pointer Sb-doped Mg{sub 2}Si pellets up to 30 mm in diameter with no internal cracks. Black-Right-Pointing-Pointer Incorporation of 5 wt% Ni binder affected an increase in the ZT value up to 0.97.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Predicting sintering window during supersolidus liquid phase sintering of steels using feedstock analysis and CALPHAD

Binder jet 3D printing results in carbon pickup from the binder at the inter-particle regions during binder burnout. The excess carbon lowers the solidus temperature of the green part locally during supersolidus liquid phase sintering (SLPS). Currently, thermodynamic calculations rely on the use of bulk powder compositions to predict the sintering window. This can overestimate the sintering temperature since the local increase in carbon on powder surfaces is not accounted for, that can locally lower the solidus temperature during SLPS. Here we show that using the inputs from feedstock and binder analysis, the excess carbon and hence the sintering window for the alloy can be predicted using CALPHAD. We present a case study on applying the proposed approach for pressureless sintering of binder jet additive manufactured (BJAM) of H13 steel via SLPS.

36 MATERIALS SCIENCE↗
DOE OSTI2023

On the confluence of ultrafast high-temperature sintering and flash sintering phenomena

Ultrafast high-temperature sintering (UHS) and flash sintering are novel methods for rapid sintering of ceramics, often completed in just a few seconds. Here, we show that both also share two additional features: an abrupt rise in electrical conductivity, which is electronic, and electroluminescence. More fundamentally, both are related to phonon physics where MD calculations have shown that proliferation of phonons at the edge of the Brillouin zone can induce Frenkel pairs without the application of electrical fields. Here, we show that, indeed, heating without the application of electric field, can also induce flash: Rapid heating processes of thin films of an oxide-salt deposited on silk fibers, with a propane torch, are shown to induce electronic conductivity, electroluminescence, and rapid sintering of the oxide. Further, the discussion in this article harkens back to two inventions, more than a century ago, which can now be related to flash and UHS: (i) the Nernst glow lamp circa 1900, made from zirconia, and (ii) the Welsbach mantle, constituted from ceria doped thorium oxide, in the late nineteenth century. Thus, the confluence between high heating rate and electric field induced flash phenomena links the past to the new. The emerging question is how injection of phonons that has been shown to create Frenkels can further induce high electronic conductivity and electroluminescence in oxides. Both electronic conductivity and luminescence are likely related to the generation of electron–hole pairs.

36 MATERIALS SCIENCE↗