Spark plasma sintering (SPARK PLASMA SINTERING, SPS) is a new technology for rapid consolidation of powders. SPS utilizes a high-current pulsed power source to excite and promote the consolidation and reactive sintering processes of materials. Compared with traditional technology, SPS can adjust the density value of various conductors, non-conductors and composite materials to any required value during the processing. SPS shortens the experimental time and energy consumption to a greater extent, while maintaining the micro-nano structure of the material. Therefore, since its birth, it has quickly become an important tool in scientific research, new material research and development, industrial production and other fields.
Features:
Product Features
1.High integration and small footprint.
2.Fast sintering speed, excellent energy efficiency, and high efficiency.
3.Uses IGBT pulsed DC heating, capable of reaching high temperatures within minutes.
4.Integrated side-opening door mechanism, with all processing positions precisely machined to ensure component assembly accuracy, maintaining concentricity and synchronization of the upper and lower pressing heads.
5.Accurate temperature measurement: Infrared instruments directly measure mold temperature for more precise readings.
6.PLC controls temperature and pressure, recording parameters such as temperature, pressure, vacuum level, and atmospheric pressure, with protection and alarms for overheating, overpressure, and overcurrent.
7.The all-stainless steel furnace body is continuously welded using an automatic welding machine, ensuring smooth welds with no defects. A helium mass spectrometer is used for vacuum leak testing, with pressure rise rate indicators reflecting actual performance, exceeding national standard minimum values.
8.The upper and lower power transmission shafts are made of special high-voltage conductive materials, insulated from the furnace body by high-temperature insulation components.
9.The pressure system comprises a servo electric push rod, force sensors, etc., ensuring stable and smooth pressure control.
Purchase information
If you are interested in our spark plasma sintering furnace, please contact us for more information and quotes.
Contact number: 156 3719 8390
Email: shirley@cysitech.com
Contact person: shirley
WeChat: 18736046549
Technical parameter
Product Name | Spark Plasma Sintering Furnace |
Product Model | CY-SPS-T3 |
Structure | Stainless steel vacuum chamber Hot Press System DC Pulsed Power Supply Vacuum System Hot Press Control System |
Output Current | DC 0-5000A (digital control, pulsed DC) |
Output Voltage | DC 0-10V (digital control) |
Pulse Frequency | 5-255 ms (adjustable), 2-1000 Hz (adjustable) |
Sintering Temperature | Max Temperature: 2000℃ (temperature and heating rate depend on sample and mold size and material; graphite molds used) |
Temperature Control System | Built-in precision temperature controller Overshoot temperature under optimal heating rate: <5℃ Temperature Accuracy: <0.1℃ |
Control System | Touchscreen and PLC Temperature and pressure control using independent PLC and color LCD touchscreen, displaying parameters such as temperature, pressure, vacuum level, and temperature-pressure curves. |
Output Type | Positive pulse |
Output Waveform | Rectangular wave |
Modulation Method | Pulse height modulation and pulse width modulation |
Sintering Temperature | Determined by sample resistivity |
Hydraulics | Fully automatic pressure operation |
Max Pressure | 3T |
Pressure Measurement | Digital display pressure gauge with overpressure alarm |
Temperature Measurement | Thermocouple and infrared temperature measurement |
Mold | Equipped with 2 sets of hot isostatic graphite molds, diameter 10-20mm |
Working Area Height | Space height for mold handling: 60mm |
Vacuum Chamber | Circular stainless steel double-layer chamber, pressure-resistant, requires cooling water supply |
Pressure Control System | PLC + touchscreen control system |
Pressure Rise Rate | ≤5Pa/hr |
Vacuum Level | 1Pa |
Pressure Stability | ≤±0.1MPa |
Heating Rate | Determined by sample resistivity, max up to 150℃/min |
Safety Devices | Emergency stop system and alarm system |
Cooling System | Equipped with a circulating water cooler, flow rate 58L/min |
Standard Accessories | SPS sintering graphite molds, clamping tools |
Control Software | Allows setting of temperature-time and pressure-time curves |
Voltage | 380V 50HZ |
Power | 30KW |
Warranty | One year |
Main parts
Name | Description |
Main machine | Spark Plasma Sintering System |
Pulsed Power Supply | The system uses an IGBT pulsed DC power supply with an amorphous soft magnetic alloy transformer core, enabling heating to exceed 2000℃ within minutes. It features automatic feedback for voltage and current, temperature detection for the medium-frequency transformer, and system fault diagnosis and protection functions. |
Water Cooling System | Composed of various valves and pipelines, the cooling water enters through a main pipe and is distributed to cooling areas such as the furnace body, furnace door, upper and lower pressing heads, transformer, and IGBT power supply. Each cooling water line has a manual valve for flow adjustment. A pressure gauge on the main inlet pipe automatically cuts off heating when water pressure drops below 0.2MPa. Temperature/flow sensors on the upper and lower pressing heads stop the process and trigger alarms during abnormal conditions. |
Pressurization System | Comprising a hydraulic system, force sensors, upper and lower pressing heads, and a control system, the press head offers high stability with no vibration. Pressure is automatically applied based on set values. The press head must withstand high pressure and temperature without deformation or oxidation, requiring excellent cooling and dynamic sealing. Both pressing heads are equipped with water cooling, and special sealing techniques ensure low contact resistance. Good pressure transmission and electrical insulation materials between the press head and press ensure effective pressure transfer and insulation. |
| 1.Gas Impurity Removal: Vacuum pumps eliminate air and gas impurities from the sintering furnace to prevent reactions that could degrade material quality. 2.Oxidation Prevention: A vacuum environment significantly reduces oxygen levels, effectively avoiding oxidation of materials, especially sensitive metals or alloys. 3.Increased Material Density: The vacuum helps minimize porosity during sintering, enhancing material density and mechanical properties. 4.Atmosphere Control: Vacuum pumps allow precise control of the sintering atmosphere, enabling the introduction of specific gases, such as inert (argon) or reducing gases (hydrogen), to achieve desired sintering effects. |
Random accessory | Related auxiliary tools such as clamps, copper strips, corrugated pipes, various standard parts, and spare parts. |
User manual | One piece |
Application fields:
1.Advanced Ceramic Materials
Functional Ceramics: SPS furnaces are used to produce high-density functional ceramics, such as piezoelectric ceramics, ferroelectric ceramics, and dielectric materials. The rapid sintering technology reduces excessive grain growth, maintaining excellent electrical and mechanical properties.
Structural Ceramics: SPS technology excels in the fabrication of high-strength, high-hardness structural ceramics (e.g., zirconia, silicon nitride, silicon carbide), commonly used in tools, bearings, and turbine blades in high-temperature and high-pressure environments.
2.Hard Alloys
Tool Manufacturing: SPS furnaces are widely used for the rapid sintering of hard alloy materials (e.g., tungsten carbide), essential for manufacturing cutting tools, drill bits, and molds. These materials possess excellent hardness and wear resistance, suitable for demanding industrial applications.
Wear-Resistant Components: SPS sintering can produce high-density, wear-resistant alloy materials, such as those used in mining and oil drilling industries.
3.Metals and Intermetallic Compounds
Powder Metallurgy: SPS furnaces facilitate the rapid sintering of metal powders and intermetallic compounds (e.g., titanium alloys, aluminum alloys, nickel-based alloys), widely used in aerospace, automotive, and defense industries. This technology rapidly densifies metal parts, enhancing their mechanical properties and corrosion resistance.
Superhard Materials: SPS technology is also applied to the sintering of superhard materials, such as diamond composites and cubic boron nitride (cBN) tool materials, used in high-performance cutting tools and drilling equipment.
4.Composite Materials
Metal Matrix Composites: SPS furnaces can sinter metal matrix composites, enhancing their tensile strength and corrosion resistance, commonly used in aerospace and automotive industries. SPS technology aids in achieving high density and uniform microstructure.
Ceramic Matrix Composites: SPS is used to fabricate ceramic matrix composites, such as silicon carbide-reinforced ceramics, which exhibit high-temperature stability and thermal shock resistance, often employed in thermal protection coatings and engine components.
5.Nanomaterials
Nanopowder Sintering: SPS technology significantly benefits the sintering of nanoscale powders, preventing excessive grain growth and maintaining the nanostructured microstructure. This is crucial for producing high-strength, low-density nanomaterials, suitable for semiconductor devices and high-performance sensors.
Superconducting Materials: SPS can also be used to sinter superconducting materials, enhancing their density and conductivity, with applications in power equipment, magnets, and sensors.
6.New Energy Materials
Lithium Battery Materials: SPS furnaces are utilized to prepare electrode materials and solid electrolytes for lithium-ion batteries, improving battery conductivity, stability, and cycle life.
Fuel Cell Materials: SPS technology can be employed for sintering electrolytes and electrode materials for solid oxide fuel cells (SOFC), shortening production time and enhancing material conductivity and mechanical strength.
7.Biomaterials
Bioceramics: SPS furnaces can produce biocompatible ceramics, such as hydroxyapatite (HAP) and β-tricalcium phosphate, used in artificial joints, orthopedic implants, and dental materials, providing excellent mechanical properties and biocompatibility.
Biocomposites: By sintering metal-ceramic composites using SPS technology, it is possible to develop higher strength and wear-resistant biomaterials, suitable for medical devices and implants.
8.Thermoelectric Materials
Thermoelectric Generation Materials: SPS is used to prepare high-performance thermoelectric materials (e.g., silicon-germanium alloys, cobaltates, bismuth-antimony alloys) that effectively convert temperature differences into electrical energy, widely applied in energy recovery and thermoelectric generation fields.
9.Magnetic Materials
Soft and Hard Magnetic Materials: SPS technology can sinter soft and hard magnetic materials, such as neodymium-iron-boron and samarium-cobalt magnets, commonly used in motors, generators, and magnetic storage devices.
10.Electronic Packaging Materials
Ceramic-Based Circuit Boards: SPS can be used to sinter electronic packaging materials, such as high thermal conductivity ceramic substrates, for semiconductor device packaging, offering excellent thermal conductivity and insulation properties, suitable for high-power electronic devices.
Application Case (Preparation of Superhard Diamond Composite Materials)
The steps for preparing superhard diamond composite materials using a Spark Plasma Sintering (SPS) furnace are as follows:
1.Raw Material Preparation
Diamond Powder: Select high-purity diamond powder, with particle sizes typically in the micron or nanometer range, based on requirements.
Binder (Metal Powder): Common binders include cobalt (Co), nickel (Ni), copper (Cu), or other metal powders. These materials bond with diamond during sintering to enhance the composite's overall strength.
Material Mixing: Combine diamond powder with metal binder powder at a specific ratio, usually 5%-20% binder, depending on application needs.
2.Powder Mixing
Uniform Mixing: Ensure thorough mixing of diamond and metal powders to achieve uniformity during sintering. Methods like ball milling or ultrasonic mixing can be used for even dispersion.
Drying Treatment: If wet mixing is used, dry the mixed powder to remove excess solvents or moisture.
3.Loading and Mold Preparation
Mold Selection: Choose high-strength, high-temperature-resistant molds (e.g., graphite or tungsten molds) for SPS sintering, with sizes and shapes tailored to the final product specifications.
Filling the Mold: Fill the mold with the uniformly mixed powder, ensuring even distribution and tight packing.
4.SPS Sintering Process
Mold Loading: Place the filled mold into the vacuum chamber of the SPS furnace, ensuring good contact between the mold and electrodes.
Vacuum or Inert Atmosphere: Start the vacuum pump to reduce pressure in the SPS chamber or introduce inert gas (e.g., argon) to prevent oxidation as needed.
Temperature Setting: Set the sintering temperature based on the characteristics of the diamond and metal binder, typically between 600°C and 1000°C. Avoid excessive temperatures to prevent diamond conversion to graphite.
Current Pulse and Pressure Setting:
Pulsed Current: SPS directly heats the mold using pulsed current, with intensity adjusted according to mold size and material properties. The heat generated rapidly raises the material temperature.
Pressure Application: Simultaneously apply high pressure to the mold via hydraulic systems, typically ranging from 30 to 100 MPa, to facilitate particle densification and bonding.
Sintering Time: SPS sintering time is relatively short, usually ranging from a few minutes to several tens of minutes, depending on material characteristics and target density.
5.Cooling and Demolding
Cooling Process: After sintering, gradually lower the chamber temperature, allowing natural cooling or using a water cooling system. Rapid cooling may cause cracking, so the cooling rate must be controlled.
Demolding: Once the material cools to room temperature, open the SPS furnace’s vacuum chamber, remove the mold, and carefully extract the sintered diamond composite material.
6.Post-Processing
Mechanical Processing: If the composite requires further shaping or sizing, operations like cutting, polishing, or drilling can be performed.
Surface Treatment: Depending on product requirements, surface treatments such as coatings or deburring may be needed to enhance smoothness or corrosion resistance.
7.Performance Testing
Microstructural Analysis: Use scanning electron microscopy (SEM) or transmission electron microscopy (TEM) to analyze the microstructure of the diamond composite, checking the bonding state between diamond particles and metal binder, as well as grain sizes.
Mechanical Property Testing: Assess hardness, flexural strength, compressive strength, and wear resistance to ensure compliance with design requirements.
Density Measurement: Conduct density tests to determine the sintered material's density and evaluate the effectiveness of the sintering process.
8.Application
Industrial Use: The prepared diamond composite materials can be applied in various high-strength, wear-resistant environments, such as drilling tools, cutting tools, and abrasive tools.
Performance Optimization: Based on the material's actual performance, adjust the ratio of diamond to metal binder and sintering process parameters to further optimize the composite's properties.
