Plasma Activated Sintering--A Novel Rapid Consolidation Manufacturing Process

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A new plasma activated sintering (PAS) process for consolidation of a variety of ceramic, intermetallic, and electronic materials will be investigated with a focus on the potential for developing a PAS manufacturing technology encompassing materials processing issues, system control, process automation, and technology transfer to US industry. The research is an interdisciplinary effort involving materials processing, manufacturing and automation. Specific research on PAS processing of Nb-Al and NiAl intermetallics and AIN rapid consolidation will be performed to create the scientific and engineering foundation of this new and powerful processing method and to develop optimal process control parameters. Based on the fundamental understanding of the mechanism of PAS consolidation, a process model will be developed. The evaluation of process parameters will be performed using modern microstructural analysis techniques (to determine phase formation, grain size, and grain boundary structure) in conjunction with density and mechanical properties measurements. Architectures and functions relevant to an advanced PAS technology for the future will also be designed as part of the research in anticipation of the potential for intelligent manufacturing by the PAS process and eventual transfer of this promising technology to US industry.