Systems, devices and methods for spark plasma sintering

Patent metadata

Field	Value
Publication number	US-11229950-B2
Application number	US-201815959617-A
Country	US
Kind code	B2
Filing date	Apr 23, 2018
Priority date	Apr 21, 2017
Publication date	Jan 25, 2022
Grant date	Jan 25, 2022

Abstract

A method of forming an article including: contacting a fugitive tool with a powdered parent material; densifying the powdered material; and destructively removing the fugitive tool. A coating of a different material may be formed against the parent material using a similar approach.

First claim

What is claimed is:

1. A method of forming an article comprising:
contacting a porous fugitive tool comprising a carbonaceous material, a silica based ceramic, or a ceramic comprising alumina, zircon and/or cristobalite with a powdered parent material; densifying the powdered material; and destructively removing the porous fugitive tool, wherein densifying employs spark plasma sintering (SPS) and destructively removing the tool comprises burning in air or leaching with a hot caustic solution;
wherein the parent material has nanoscale morphology.

2. The method of claim 1 , wherein the porous fugitive tool is embedded in the powdered parent material.

3. The method of claim 1 , further comprising placing the porous fugitive tool in contact with a non-fugitive tool.

4. A method of forming a coating comprising applying a coating material to a porous fugitive tool comprising a carbonaceous material, a silica based ceramic, or a ceramic comprising alumina, zircon and/or cristobalite; placing powdered parent material in contact with the coating material on the porous fugitive tool; densifying the powdered parent material and destructively removing the porous fugitive tool, wherein densifying employs spark plasma sintering (SPS) and destructively removing the tool comprises burning in air or leaching with a hot caustic solution;
wherein the parent material has nanoscale morphology.

5. The method of claim 4 , wherein the porous fugitive tool is embedded in the powdered parent material.

6. The method of claim 4 , further comprising placing the porous fugitive tool in contact with a non-fugitive tool.

7. The method of claim 4 , wherein the coating imparts catalytic reactivity to the surface of the densified parent material.

8. A method of locating an interior component comprising contacting a component with a porous fugitive tool comprising a carbonaceous material, a silica based ceramic, or a ceramic comprising alumina, zircon and/or cristobalite; placing the porous fugitive tool in a non-fugitive tool; placing powdered parent material in contact with the porous fugitive tool; densifying the powdered parent material and destructively removing the porous fugitive tool wherein densifying employs spark plasma sintering (SPS) and destructively removing the tool comprises burning in air or leaching with a hot caustic solution.

9. The method of claim 8 , wherein the porous fugitive tool is embedded in the powdered parent material.

10. The method of claim 8 , further comprising placing the porous fugitive tool in contact with the non-fugitive tool.

11. The method of claim 8 , wherein the parent material has nanoscale morphology.

Assignees

• Mikro Systems Inc
• Raytheon Tech Corp

Inventors

• Paulus John R
• Moore Jon T
• Heneveld Benjamin E

Classifications

• B22F3/105 Primary

  by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)} · CPC title

• B22F2003/1046

  with separating means for articles to be sintered · CPC title

• B22F2003/248

  Thermal after-treatment · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• C04B2235/666

  Applying a current during sintering, e.g. plasma sintering [SPS], electrical resistance heating or pulse electric current sintering [PECS] · CPC title