Development of Ti PVD Films to Limit the Carburization of Metal Powders during SPS Process

Abstract

Spark plasma sintering technique is used for the fabrication of dense materials with a fine-grained microstructure. In this process, a powder is placed into a graphite mold and a uniaxial pressure is applied by two graphite punches. A graphite foil is inserted between the punches and the powder and between the mold and the powder to ensure good electrical, physical and thermal contact. One of the major drawbacks during sintering of metal powders is the carburization of the powder in contact with the graphite foils. In this study, a PVD coating of titanium was applied on the graphite foils in contact with the metal powder (pure iron). The results are promising, as the investigations show that the application of a Ti PVD film of 1.5 and 1.1 µm thickness is effective to completely avoid the carburization of iron powder. Carbon diffuses inside the PVD film during sintering. In parallel, iron diffusion was revealed inside the Ti coating of 1.5 µm thickness. On the other hand, a Ti PVD film of 0.5 µm thickness provides a protection against carbon diffusion just on the sides in contact with the mold, proving that the coating thickness represents an important parameter to consider.

Tooling in Spark Plasma Sintering Technology: Design, Optimization, and Application

“…A solution might be the use of graphite foil coated with a nonreactive conductive material. [ 80 ] However, even in such a case, the reducing environment inside the FAST/SPS die cannot fully exclude the interaction of the sintered material with carbon monoxide or CO 2 . [ 2 ]…”