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Method for creating functionally graded materials with spark plasma sintering and a continuous machine for future scalability

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dc.contributor.authorColasuonno, Paul S., author
dc.contributor.authorJames, Susan, advisor
dc.contributor.authorMa, Kaka, committee member
dc.contributor.authorNeilson, James, committee member
dc.date.accessioned2018-01-17T16:46:21Z
dc.date.available2018-01-17T16:46:21Z
dc.date.issued2017
dc.description.abstractThis work develops a quantitative process to sinter functionally graded materials (FGMs) to specific porosity gradients using Spark Plasma Sintering (SPS). The powder densification in SPS is modeled using the Master Sintering Curve (MSC) calculated from shrinkage due to three different heating rates. The meaning of the apparent sintering activation energy is discussed along with the MSC's applicability to SPS. The MSC is adjusted for the additional sintering that occurs during cooling, such that porous materials can be produced by interrupting the heating schedule. The temperature in the powder is then spatially resolved by a constructed thermal-electric FEA model. Tooling is designed to apply a steady state temperature gradient (50°C/mm) on zirconia (+3% mol yttria) powder. The MSC, coupled to the thermal-electric model, is used to spatially predict densification in a temperature gradient. Resulting FGM microstructures and grain size distributions are discussed. Design problems found while attempting to scale the FGMs process to larger diameters are quantified. As an alternative to traditional SPS batch processes, a Continuous Electric Field Assisted Sintering (CEFAS) machine is developed to address these practical limitations from a new direction. The proof of concept CEFAS machine uses Joule heated rollers to continuously heat, compress, and extrude material under conditions analogous to SPS. Design considerations, lessons learned, and control variables for future iteration CEFAS machines are illustrated.
dc.format.mediumborn digital
dc.format.mediummasters theses
dc.identifierColasuonno_colostate_0053N_14608.pdf
dc.identifier.urihttps://hdl.handle.net/10217/185776
dc.languageEnglish
dc.language.isoeng
dc.publisherColorado State University. Libraries
dc.relation.ispartof2000-2019
dc.rightsCopyright and other restrictions may apply. User is responsible for compliance with all applicable laws. For information about copyright law, please see https://libguides.colostate.edu/copyright.
dc.subjectcontinuous electric field assisted sintering
dc.subjectfunctionally graded materials
dc.subjectspark plasma sintering
dc.subjectelectric field assisted sintering
dc.subjectceramics engineering
dc.subjectmaster sintering curve
dc.titleMethod for creating functionally graded materials with spark plasma sintering and a continuous machine for future scalability
dc.typeText
dcterms.rights.dplaThis Item is protected by copyright and/or related rights (https://rightsstatements.org/vocab/InC/1.0/). You are free to use this Item in any way that is permitted by the copyright and related rights legislation that applies to your use. For other uses you need to obtain permission from the rights-holder(s).
thesis.degree.disciplineMechanical Engineering
thesis.degree.grantorColorado State University
thesis.degree.levelMasters
thesis.degree.nameMaster of Science (M.S.)

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