Electric Current Assisted Sintering
These techniques employ electric currents to drive or enhance sintering. English engineer A. G. Bloxam registered in 1906 the first patent on sintering powders using direct current in vacuum. The primary purpose of his inventions was the industrial scale production of filaments for incandescent lamps by compacting tungsten or molybdenum particles. The applied current was particularly effective in reducing surface oxides that increased the emissivity of the filaments.
In 1913, Weintraub and Rush patented a modified sintering method which combined electric current with pressure. The benefits of this method were proved for the sintering of refractory metals as well as conductive carbide or nitride powders. The starting boron–carbon or silicon–carbon powders were placed in an electrically insulating tube and compressed by two rods which also served as electrodes for the current. The estimated sintering temperature was 2000 °C.
In the US, sintering was first patented by Duval d’Adrian in 1922. His three-step process aimed at producing heat-resistant blocks from such oxide materials as zirconia, thoria or tantalia. The steps were: (i) molding the powder; (ii) annealing it at about 2500 °C to make it conducting; (iii) applying current-pressure sintering as in the method by Weintraub and Rush.
Sintering which uses an arc produced via a capacitance discharge to eliminate oxides before direct current heating, was patented by G. F. Taylor in 1932. This originated sintering methods employing pulsed or alternating current, eventually superimposed to a direct current. Those techniques have been developed over many decades and summarized in more than 640 patents.
Of these technologies the most well known is resistance sintering (also called hot pressing) and spark plasma sintering, while capacitor discharge sintering is the latest advancement in this field.
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