Spark Plasma Sintering Process (SPS)

Spark Plasma Sintering or FAST sintering

An innovative powder metallurgy process

Powder metallurgy involves several techniques: metal injection molding (MIM), hot isostatic pressing (HIP), additive manufacturing, etc.

SINTERMAT in industrializing a new and innovative powder metallurgy process: Spark Plasma Sintering (SPS), also known as FAST sintering or flash sintering.

Spark Plasma Sintering involves fusing powders under the simultaneous effect of a strong electrical pulse and uniaxial loading, thereby obtaining high strength and high-density parts.

Through this process, the densification of powders and materials can generally be achieved 10 to 100 times faster than by conventional sintering techniques.

It enables the synthesis of solid, innovative, original and controlled microstructure materials at moderate cost.

It is one of the only technologies capable of producing materials with microstructures without enlarging the grain and with a densification rate close to 100%.

The advantages of Spark Plasma Sintering

Improved technical characteristics

The Spark Plasma Sintering process enables the development of materials with unprecedented technical characteristics:
greater strength, higher density, improved hardness, extended service life, light weight, etc.
It also guarantees hot stability properties.
Stability and the precise control of settings give high reliability and an excellent reproduction capacity of parts.
This allows these high performance materials to meet exacting requirements in sectors such as
the aeronautical, security/defense, health, automotive and energy industries.

A quick production cycle

The Spark Plasma Sintering method is easy to implement. Just a few grams of powder are enough to give a fairly accurate idea of the sintering conditions.
Some parts may be produced in under one hour.
Contrary to conventional techniques, there are fewer production stages: pre-compaction, sintering and cooling.
Depending on part complexity, it may even be possible to skip the machining stage.

Complex design parts

Because of this innovative process that enables the assembly of several materials without requiring any additives, new materials can be made:
for example, the combination of ceramic and metal
The unique aesthetic qualities of the parts and the numerous customization and combination options offer limitless creativity.

Eco-friendly product and technology

The SPS process works using industrial materials (metal, ceramics, etc.) as well as bio-based materials (wood, plants, etc.).
Materials of different types may be joined without the addition of any other materials or additives.
The number of high energy-consuming manufacturing operations is reduced.
Near Net Shape or Net Shape production enables bare minimum consumption of raw materials.
Heating and cooling are controlled to reduce the carbon footprint.
The material obtained can revery back to a raw material and this pattern repeats itself in an infinite virtuous cycle (circular economy, recycling).

From powder to materials : how does Spark Plasma Sintering works ?

The Spark Plasma Sintering process compacts powders in a graphite mold, applying uniaxial pressure of around 200 MPa.

Very short, high-intensity electric pulses are passed through the mold and the powder. The mold and the sample may reach temperatures of up to 2400°C and ramps of up to 1000°C per minute.

The material condenses under the effect of the pressure, generating compact nano-structured parts with improved characteristics: augmented materials.

FAST sintering works on many types of materials: conductive and magnetic materials, metals, polymers, ceramics, composites, bio-materials, etc. Furthermore, it enables parts to be created that combine several materials: multi-material components.

The process is ideal for making parts that are complex in shape, such as teeth, grooves, non-axisymmetric profiles and shapes that can be produced directly from tools, without the need for machining.

Original materials

Unique know-how

The materials are ground into a powder. SINTERMAT then transforms the powder into blocks (or slugs) through sintering, without adding binders or additives and by controlling the heating and cooling.

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Have you got a project?

Do you want to offer innovative products and unique materials to your customers? Would you like to improve your parts? Do you wish you could recycle your production scrap? Contact us today.