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Enhanced Sintering Kinetics in Aluminum Alloy Powder Consolidated Using DC Electric Fields

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Abstract

Direct current (DC) electric currents were applied during sintering of aluminum alloy (AA5083) green powder compacts and it was found that the kinetics of sintering were greatly enhanced compared to samples processed without a field. In situ sintering kinetics during pressure-less sintering employing electric field strengths and amperages ranging from 0 to 56 V/cm and 0 to 3 A were quantified using digital image correlation. It was found that the application of a DC field during sintering results in a discontinuous change in volume at a critical temperature along with a transition in electrical properties of the compact from insulating to conductive. This effect is similar to the phenomena observed in the flash sintering process currently being actively researched for ceramic powder processing. The temperature at which the flash event occurs was found to be field strength dependent and doubling the field strength was found to decrease the flash temperature by 25 pct. Joule heating of the specimen was measured using thermal imaging and it was found to not contribute enough additional thermal energy to account for the substantially increased sintering rates observed in specimens processed using electric fields.

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Authors and Affiliations

  1. U.S. Army Research Laboratory, Weapons & Materials Research Directorate, Aberdeen Proving Ground, Aberdeen, MD, 21005, USA

    Brandon McWilliams (Materials Engineer) & Jian Yu (Materials Engineer)

  2. Bowhead Science and Technology, Belcamp, MD, 21017, USA

    Frank Kellogg (Research Engineer)

  3. TKC Global, Herndon, VA, 20171, USA

    Steven Kilczewski (Research Engineer)

Authors
  1. Brandon McWilliams
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  2. Jian Yu
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  3. Frank Kellogg
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  4. Steven Kilczewski
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Correspondence to Brandon McWilliams.

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Manuscript submitted May 26 2016.

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McWilliams, B., Yu, J., Kellogg, F. et al. Enhanced Sintering Kinetics in Aluminum Alloy Powder Consolidated Using DC Electric Fields. Metall Mater Trans A 48, 919–929 (2017). https://doi.org/10.1007/s11661-016-3861-4

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