SINTERING APPLICATIONS Edited by Burcu Ertuğ Sintering Applications http://dx.doi.org/10.5772/56064 Edited by Burcu Ertuğ Contributors Faming Zhang, Eberhard Burkel, Yujie Quan, Christoph Schweigel, Olaf Kessler, Narla Sharma, Hongfang Zhang, Chee- Leung Mak, Helen Lai Wa Chan, Xi Yao, Rosidah Alias, José Holanda, Chunping Zhang, Baojun Zhao, Nilgun Kuskonmaz, Guido Falk, Adolfo Fernández, Ramón Torrecillas, J.L Menendez, Marta Suárez, Waldemar Monteiro, Amin Salem, Burcu Ertug Published by InTech Janeza Trdine 9, 51000 Rijeka, Croatia Copyright © 2013 InTech All chapters are Open Access distributed under the Creative Commons Attribution 3.0 license, which allows users to download, copy and build upon published articles even for commercial purposes, as long as the author and publisher are properly credited, which ensures maximum dissemination and a wider impact of our publications. 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Publishing Process Manager Danijela Duric Technical Editor InTech DTP team Cover InTech Design team First published February, 2013 Printed in Croatia A free online edition of this book is available at www.intechopen.com Additional hard copies can be obtained from orders@intechopen.com Sintering Applications, Edited by Burcu Ertuğ p. cm. ISBN 978-953-51-0974-7 free online editions of InTech Books and Journals can be found at www.intechopen.com Contents Preface VII Section 1 Sintering Of Ceramics 1 Chapter 1 Oxide Ceramic Functional Thin Layer Processing by Thermal and Laser Sintering of Green Layers 3 Guido Falk, Katrin Klein and Christoph Rivinius Chapter 2 Powder Preparation, Properties and Industrial Applications of Hexagonal Boron Nitride 33 Burcu Ertuğ Chapter 3 High Pressure Sintering of Nano-Size γ-Al2O3 57 Nilgun Kuskonmaz Chapter 4 Sintering Behavior of Vitrified Ceramic Tiles Incorporated with Petroleum Waste 73 A.J. Souza, B.C.A. Pinheiro and J.N.F. Holanda Chapter 5 Structural and Dielectric Properties of Glass – Ceramic Substrate with Varied Sintering Temperatures 89 Rosidah Alias Chapter 6 Low Temperature Hybrid Processing Technology of Fine Electronic Ceramics 119 Hongfang Zhang, Chee-leung Mak, Helen Lai-Wa Chan and Xi Yao Section 2 Sintering Of Metals 143 Chapter 7 Sintering of Ternary Copper Alloys (Powder Metalurgy) – Electrical and Mechanical Properties Effects 145 W. A. Monteiro, J. A. G. Carrió, M. A. Carvalhal, A. K. Okazaki, C. R. da Silveira and M. V. S. Martins Chapter 8 Lead and Zinc Sintering 165 Baojun Zhao Chapter 9 Pulse Current Auxiliary Sintering 201 Zhang Chunping and Zhang Kaifeng Chapter 10 Development of a Stress Insensitive MgCuZn-NiCuZn Composite Ferrite Useful for Microinductors Applications 229 N. Varalaxmi and K. Sivakumar Chapter 11 Sintering and Heat Treatment of Titanium Alloys by Pulsed Electric Current Sintering 259 F. Zhang, Y. Quan, M. Reich, O. Kessler and E. Burkel Section 3 Basic Sintering 285 Chapter 12 Mechanisms of Momentum Transport in Viscous Flow Sintering 287 Shiva Salem and Amin Salem Chapter 13 Challenges and Opportunities for Spark Plasma Sintering: A Key Technology for a New Generation of Materials 319 M. Suárez, A. Fernández, J.L. Menéndez, R. Torrecillas, H. U. Kessel, J. Hennicke, R. Kirchner and T. Kessel ContentsVI Preface Materials science and engineering depends on three classes of materials namely metals, ce‐ ramics and polymers. The aim of this book is to help the graduate and doctoral students in materials science and related disciplines on the sintering of several materials. During the sintering process, changes occur in the microstructure because of decomposition or phase transformations. Three major changes commonly ocur during sintering. The grain size increases, pore shape and pore size changes. The result is a decrease in the porosity after sintering. The fabrication process for ceramics involves several different steps. The first step in ceramics processing is compaction. In the compaction stage, ceramic powders are pressed in a die to shape the powder into the desired form. Sintering is one of the final stages of ceramics fabrication and is used to increase the strength of the compacted material. In the Sintering of Ceramics section, the fabrication of electronic ceramics and glass-ceramics were presented. Especially dielectric properties were focused on. In other chapters, sintering behaviour of ceramic tiles and nano-alumina were investigated. Apart from oxides, the sin‐ tering of non-oxide ceramics was examined. Powder metallurgy manufacturing technology consists of three steps; mixing elemental or alloy powders, compacting those powders in a die at room temperature and then sintering or heating the shape in a controlled atmosphere furnace to bond the particles together met‐ allurgically. In the Sintering of Metals section, two sections dealt with copper containing structures. The sintering of titanium alloys is another topic focused in this section. The chap‐ ter on lead and zinc covers the sintering in the field of extractive metallurgy. Finally two more chapter focus on the basics of sintering,i.e viscous flow and spark plasma sintering. Dr.Burcu Ertug Istanbul Technical University, Department of Metallurgical and Materials Engineering, Istanbul, Turkey Section 1 Sintering Of Ceramics [...]... sin‐ 27 28 Sintering Applications tering programs used resulted in crack-free co-sintered composites During sintering investi‐ gations, a specific impact of the green in the sintering microstructure was observed: Increased green densities generally result in increased grain growth effects The two-stepsintering approach enables the complete densification of the sintered YSZ layers at a maxi‐ mum sintering. .. will facilitate the 7 8 Sintering Applications laser sintering process and might lead to the bypassing of complex powder accumulation and pre -sintering processing steps For example, electrophoretically deposited alumina green layers have already been laser sin‐ tered on standard chromium and chromium-nickel steels, though under inert gas atmos‐ phere conditions [46] Moreover, laser sintering of powdered... 7500 mm/s The following Figure 5 depicts the laser equipment used for the laser sintering and densification of green ceramic thin films Figure 5 Prototypical CO2-laser sintering facility used for sintering and densification of green thin film ceramic layers Oxide Ceramic Functional Thin Layer Processing by Thermal and Laser Sintering of Green Layers http://dx.doi.org/10.5772/53257 Through the use of... material and the substrate is achieved (b3) Oxide Ceramic Functional Thin Layer Processing by Thermal and Laser Sintering of Green Layers http://dx.doi.org/10.5772/53257 4 Thermal processing of thin YSZ-electrolytes for SOFC applications 4.1 Sintering of YSZ thin films We investigated the influence of sintering parameters on micro-structure of electrolyte and anode substrate respectively for given EPD boundary... differential thermogravimetry and dilatometry up to 1500 °C was used, in order to compare sintering shrinkage of anode substrates between one-step sintering and two-step -sintering approach The following Figure 15 shows the porosities of the anode substrates as well as the YSZ grain sizes achieved as a function of the thermal sintering methodology used Figure 15 Porosities of the anode substrate and YSZ grain... Figure 16, it is evident that electrolytes sintered by two-step -sintering show significantly increased densi‐ fication The better suitability of two-step-sintered electrolyte layers can easily be seen in Figure 16 b Here, a full densification of the electrolyte thin film was only achieved dur‐ ing the second sintering step 19 20 Sintering Applications Figure 16 SEM topographies of breaking edges of two-step-sintered... be put into relation with experimental data and observed findings If conditions of constrained sintering are met significant sintering stresses will appear with‐ in thin layers that result in reduced densification rates[42, 43] Additionally, in the specific case of sintering thick layers the constrained sintering condition is only applied alongside surfaces of the sintered body By that way, the free... µm However, a sintering temperature of 1350 °C is necessary in order to guarantee the electrical conductivity of the NiO-YSZ anode support Reducing sintering atmospheres would result in an increase of the anode porosity, inde‐ pendent of the sintering programs used previously The total porosity after anode reduction to the Ni-YSZ-system consists of the porosity achieved after two-step -sintering and... to the factory default level of 7477 mm/s (a) (b) (a) (b) Figure 6 Schematic of the experimental laser sintering and densification setup with the option of defocused opera‐ tion (a) and focused operation mode (b) 3.2 Laser sintering and laser consolidation Processes of laser consolidation and laser sintering comprise the scanning the sample sur‐ face by a focused laser beam The motion system is usually... converted bitmap (b) 15 16 Sintering Applications Laser travel speed as well as laser power will be adopted after the conversion of the tem‐ plate into the scanner bitmap format However, line spacing is influenced by the pixel size The scanning unit controls line by line the individual pixels This process refers to the scan‐ ning with a laser travel speed vscan analogous to the laser sintering process Depending . SINTERING APPLICATIONS Edited by Burcu Ertuğ Sintering Applications http://dx.doi.org/10.5772/56064 Edited by Burcu Ertuğ Contributors Faming. laser sintering and densification of green ceramic thin films. Figure 5. Prototypical CO 2 -laser sintering facility used for sintering and densification of green thin film ceramic layers. Sintering. Ferrite Useful for Microinductors Applications 229 N. Varalaxmi and K. Sivakumar Chapter 11 Sintering and Heat Treatment of Titanium Alloys by Pulsed Electric Current Sintering 259 F. Zhang, Y. Quan,