Review: liquid phase sintering

Liquid phase sintering (LPS) is a process for forming high performance, multiple-phase components from powders. It involves sintering under conditions where solid grains coexist with a wetting liquid. Many variants of LPS are applied to a wide range of engineering materials. Example applications for this technology are found in automobile engine connecting rods and high-speed metal cutting inserts. Scientific advances in understanding LPS began in the 1950s. The resulting quantitative process models are now embedded in computer simulations to enable predictions of the sintered component dimensions, microstructure, and properties. However, there are remaining areas in need of research attention. This LPS review, based on over 2,500 publications, outlines what happens when mixed powders are heated to the LPS temperature, with a focus on the densification and microstructure evolution events.

[1]  R. Tolman The Effect of Droplet Size on Surface Tension , 1949 .

[2]  Hyoun‐Ee Kim,et al.  Variation of WC grain shape with carbon content in the WC–Co alloys during liquid-phase sintering , 2003 .

[3]  W. Kingery,et al.  Densification During Sintering in the Presence of a Liquid Phase. II. Experimental , 1959 .

[4]  P. Voorhees,et al.  A study of the coarsening of liquid-solid mixtures using synchrotron radiation microradiography , 1987 .

[5]  F. Delannay,et al.  Equilibrium distribution of liquid during liquid phase sintering of composition gradient materials , 2005 .

[6]  Suk‐Joong L. Kang,et al.  Theoretical analysis of liquid-phase sintering: Pore filling theory , 1998 .

[7]  R. German Sintering theory and practice , 1996 .

[8]  R. Warren,et al.  The effect of cobalt content on the microstructure of liquid-phase sintered TaCCo alloys , 1974 .

[9]  R. Watanabe,et al.  The Growth of Solid Particles in Fe-20 wt% Cu Alloy during Sintering in the Presence of a Liquid Phase , 1973 .

[10]  R. Raj Morphology and Stability of the Glass Phase in Glass Ceramic Systems , 1981 .

[11]  W. Kaysser,et al.  Shape accommodation during grain growth in the presence of a liquid phase , 1985 .

[12]  Randall M. German,et al.  Liquid Phase Sintering , 1985 .

[13]  T. Shaw Model for the Effect of Powder Packing on the Driving Force for Liquid‐Phase Sintering , 1993 .

[14]  L. Falk Imaging and microanalysis of liquid phase sintered silicon-based ceramic microstructures , 2004 .

[15]  E. Olevsky,et al.  Effect of gravity on dimensional change during sintering—II. Shape distortion , 2000 .

[16]  N. M. Parikh,et al.  Cermets: II, Wettability and Microstructure Studies in Liquid‐Phase Sintering , 1957 .

[17]  H. Riedel,et al.  Multi-Scale Simulations of Rearrangement Effects and Anisotropic Behaviour during Sintering , 2006 .

[18]  R. German,et al.  Application of percolation theory in predicting shape distortion during liquid-phase sintering , 1999 .

[19]  D. Yoon,et al.  Effect of dihedral angle on the morphology of grains in a matrix phase , 1985 .

[20]  J. K. Lee,et al.  An analysis for estimating the probability of particle coalescence in liquid phase sintered systems , 1980 .

[21]  R. German,et al.  Microstructure quantification procedures in liquid-phase sintered materials , 1999 .

[22]  M. Ferrante,et al.  Liquid formation and microstructural evolution during re-heating and partial melting of an extruded A356 aluminium alloy , 2005 .

[23]  P. Voorhees,et al.  Ostwald ripening during liquid phase sintering—Effect of volume fraction on coarsening kinetics , 1984 .

[24]  R. German,et al.  Microstructure effect on dihedral angle in liquid-phase sintering , 2001 .

[25]  A. V. Shatov,et al.  The shape of WC crystals in cemented carbides , 1998 .

[26]  D. Yoon,et al.  Grain growth and densification during liquid phase sintering of W-Ni , 1979 .

[27]  H. Andren,et al.  Development of cermet microstructures during sintering , 2001 .

[28]  G. P. Cherepanov Physics of Sintering , 1997 .

[29]  R. B. Potts Some generalized order-disorder transformations , 1952, Mathematical Proceedings of the Cambridge Philosophical Society.

[30]  R. German,et al.  Sintering atmosphere effects on tensile properties of heavy alloys , 1988 .

[31]  Dihedral angle measurement in microgravity liquid phase sintered microstructures , 2003 .

[32]  D. Clarke,et al.  Morphological Changes of an Intergranular Thin Film in a Poly crystalline Spinel , 1982 .

[33]  Andrew Crowson,et al.  Tungsten and tungsten alloys recent advances : proceedings of a symposium by the Refractory Metals Committee, held at the 120th Annual Meeting of The Minerals, Metals & Materials Society in New Orleans, Louisiana, February 17-22, 1991 , 1991 .

[34]  G. Messing,et al.  Liquid‐Phase Sintering of Alumina Coated with Magnesium Aluminosilicate Glass , 2005 .

[35]  W. Kingery,et al.  Sintering of Oxide and Carbide‐Metal Compositions in Presence of a Liquid Phase , 1961 .

[36]  M. Ashby,et al.  Role of Surface Redistribution in Sintering by Grain Boundary Transport , 1980 .

[37]  E. Lavernia,et al.  Growth Inhibition of Nano WC particles in WC-Co Alloys during Liquid-Phase Sintering , 2003 .

[38]  H. Fischmeister,et al.  A modified model for the sintering of tungsten with nickel additions , 1972 .

[39]  R. German,et al.  Densification behavior of tungsten heavy alloy based on master sintering curve concept , 2006 .

[40]  R. German,et al.  Gravity and configurational energy induced microstructural changes in liquid phase sintering , 1988 .

[41]  Z. Fang,et al.  Influence of particle size distribution on coarsening , 1992 .

[42]  R. German,et al.  Gravity induced solid grain packing during liquid phase sintering , 1995 .

[43]  D. Clarke On the Equilibrium Thickness of Intergranular Glass Phases in Ceramic Materials , 1987 .

[44]  Computer simulation of grain growth of intermediate—and final-stage sintering and Ostwald ripening of BaTiO3-based PTCR ceramics , 2003 .

[45]  D. Clarke,et al.  The Intergranular Phase in Hot‐Pressed Silicon Nitride: I, Elemental Composition , 1981 .

[46]  J. R. Jurado,et al.  Effect of Sintering Atmosphere on the Densification and Electrical Properties of Alumina , 1990 .

[47]  E. Medvedovski Liquid-phase sintering from the high-temperature corrosion process standpoint , 2001 .

[48]  R. German,et al.  Grain growth kinetics in liquid-phase-sintered zinc oxide-barium oxide ceramics , 1991 .

[49]  R. German,et al.  Grain growth in liquid-phase-sintered W-Mo-Ni-Fe alloys , 1991 .

[50]  R. German,et al.  Porosity effect on densification and shape distortion in liquid phase sintering , 2001 .

[51]  P. Nash,et al.  The effect of volume fraction of precipitate on ostwald ripening , 1980 .

[52]  W. Beere,et al.  A unifying theory of the stability of penetrating liquid phases and sintering pores , 1974 .

[53]  H. Ryoo,et al.  Anisotropic grain growth based on the atomic adsorption model in WC-25 pct Co alloy , 2000 .

[54]  D. Yoon,et al.  Coarsening of tungsten grains in liquid nickel-tungsten matrix , 1978 .

[55]  A. Gusak,et al.  INTERDIFFUSION AND SOLID STATE REACTIONS IN POWDER MIXTURES—ONE MORE MODEL , 1998 .

[56]  O. Kwon,et al.  The critical grain size for liquid flow into pores during liquid phase sintering , 1986 .

[57]  P. Markondeya Raj,et al.  Anisotropic shrinkage during sintering of particle-oriented systems—numerical simulation and experimental studies , 2002 .

[58]  A. Ardell,et al.  The effect of volume fraction on particle coarsening: theoretical considerations , 1972 .

[59]  R. German,et al.  Sintering Atmosphere Effects on the Ductility of W- Ni- Fe Heavy Metals , 1984 .

[60]  R. German,et al.  Densification and shape retention in supersolidus liquid phase sintering , 1999 .

[61]  H. Fredriksson,et al.  Penetration of tungsten grain boundaries by a liquid W-Ni-Fe matrix , 1995 .

[62]  R. Watanabe,et al.  Multi-Layered Potts Model Simulation of the Formation of Graded Structure in lron-Copper Liquid-Phase-Sintered Alloy , 2003 .

[63]  D. Clarke,et al.  Microstructure of Y2O3 Fluxed Hot‐Pressed Silicon Nitride , 1978 .

[64]  K. Hayashi,et al.  Effect of Sintering Cooling Rate on V Segregation Amount at WC/Co Interface in VC-doped WC-Co Fine-Grained Hardmental , 2004 .

[65]  Z. Nikolic Computer simulation of grain growth by grain boundary migration during liquid phase sintering , 1999 .

[66]  D. Yoon,et al.  Coarsening of cobalt grains dispersed in liquid copper matrix , 1981 .

[67]  John L. Johnson,et al.  Solid-state contributions to densification during liquid-phase sintering , 1996 .

[68]  Ralf Riedel,et al.  Handbook of ceramic hard materials. , 2000 .

[69]  G. Petzow,et al.  Elimination of Pores During Liquid Phase Sintering of Mo—Ni , 1984 .

[70]  R. German,et al.  Multiple grain growth events in liquid phase sintering , 2001 .

[71]  C. Morton,et al.  The temperature ranges for maximum effectiveness of grain growth inhibitors in WC–Co alloys , 2005 .

[72]  John L. Johnson,et al.  Effects of tungsten particle size and copper content on densification of liquid-phase-sintered W-Cu , 2005 .

[73]  G. Messing,et al.  Kinetic Analysis of Solution‐Precipitation During Liquid‐Phase Sintering of Alumina , 1990 .

[74]  A. Rollett,et al.  Three-dimensional simulation of isotropic coarsening in liquid phase sintering I: A model , 2007 .

[75]  Ronald F. Boisvert,et al.  Numerical simulation of morphological development during Ostwald ripening , 1988 .

[76]  Richard E. Toth,et al.  Liquid phase sintering of tough coated hard particles , 2005 .

[77]  O. Biest,et al.  Modelling of metal-binder migration during liquid-phase sintering of graded cemented carbides , 2005 .

[78]  J. A. Pask,et al.  Wetting under chemical equilibrium and nonequilibrium conditions , 1974 .

[79]  Three-dimensional modeling of the grain growth by coalescence in the initial stage of liquid phase sintering , 2003 .

[80]  J. Moon,et al.  Elimination of large Pores During Gas‐Pressure Sintering of β′‐Sialon , 1989 .

[81]  J. D. Wood,et al.  Elevated temperature compressive creep behavior of tungsten carbide-cobalt alloys , 1968 .

[82]  Z. Nikolic Computer Simulation of Grain Coarsening during Liquid Phase Sintering , 2005 .

[83]  W. Kaysser,et al.  Analysis of particle growth by coalescence during liquid phase sintering , 1984 .

[84]  D. C. Blaine,et al.  Application of Work-of-sintering concepts in powder metals , 2006 .

[85]  S. Sarian,et al.  Kinetics of Coarsening of Spherical Particles in a Liquid Matrix , 1966 .

[86]  John L. Johnson,et al.  Grain growth behavior of tungsten heavy alloys based on the master sintering curve concept , 2006 .

[87]  R. Carlsson,et al.  Homogeneous Distribution of Sintering Additives in Liquid-Phase Sintered Silicon Carbide , 1995 .

[88]  C. B. Carter,et al.  Glass/Crystal Interfaces in Liquid-Phase Sintered Materials , 2000 .

[89]  G. Messing,et al.  A theoretical analysis of solution-precipitation controlled densification during liquid phase sintering , 1991 .

[90]  E. Olevsky,et al.  Modeling grain growth dependence on the liquid content in liquid-phase-sintered materials , 1998 .

[91]  R. Dehoff A geometrically general theory of diffusion controlled coarsening , 1991 .

[92]  S. Luyckx,et al.  The dependence of the contiguity of WC on Co content and its independence from WC grain size in WC–Co alloys , 2006 .

[93]  H. Matsubara Computer simulation studies on sintering and grain growth , 2005 .

[94]  W. Kaysser,et al.  Particle growth by coalescence during liquid phase sintering of Fe-Cu , 1984 .

[95]  R. German,et al.  Finite element modeling of distortion during liquid phase sintering , 1998 .

[96]  V. Tikare,et al.  Numerical simulation of grain growth in liquid phase sintered materials—I. Model , 1998 .

[97]  G. Gessinger,et al.  Powder metallurgy of superalloys , 1984 .

[98]  H. Riedel,et al.  A model for liquid phase sintering , 1996 .

[99]  J. Powers,et al.  Grain Boundary Migration in Ceramics , 1998 .

[100]  J. Chaix,et al.  Computer simulation of particle rearrangement in the presence of liquid , 1999 .

[101]  A. Evans,et al.  Liquid-Phase Sintering of Ceramics , 1987 .

[102]  Y. Chung,et al.  Effect of Grain Growth on Pore Coalescence During the Liquid‐Phase Sintering of MgO‐CaMgSiO4 Systems , 1988 .

[103]  Veena Tikare,et al.  Numerical simulation of grain growth in liquid phase sintered materials—II. Study of isotropic grain growth , 1998 .

[104]  S. Stemmer,et al.  Evolution of grain boundary films in liquid phase sintered silicon nitride during high-temperature testing , 1998 .

[105]  M. Hauschild,et al.  A search for neutral Higgs bosons in the MSSM and models with two scalar field doublets , 1998 .

[106]  A. Gokhale,et al.  Effect of gravity on three-dimensional coordination number distribution in liquid phase sintered microstructures , 1999 .

[107]  R. German,et al.  Shape distortion in liquid-phase-sintered tungsten heavy alloys , 1998 .

[108]  L. Lindau,et al.  Grain Growth in TiC—Ni—Mo and TiC—Ni—W Cemented Carbides , 1976 .

[109]  N. M. Parikh,et al.  Cermets: I, Fundamental Concepts Related to Micro‐structure and Physical Properties of Cermet Systems , 1956 .

[110]  H. Fischmeister,et al.  A model for second-stage liquid-phase sintering with a partially wetting liquid , 1973 .

[111]  Walter Villanueva,et al.  Some generic capillary-driven flows , 2006 .

[112]  H. Matsubara Computer simulations for the design of microstructural developments in ceramics , 1999 .

[113]  M. Nathan,et al.  ON THE KINETIC MECHANISM OF GRAIN BOUNDARY WETTING IN METALS , 1999 .

[114]  Shun-Tian Lin,et al.  Microstructural evolution on the sintered properties of W-8 pct Mo-7 pct Ni-3 pct Fe alloy , 2000 .

[115]  R. Warren Microstructural development during the liquid-phase sintering of two-phase alloys, with special reference to the NbC/Co system , 1968 .

[116]  W. Kingery,et al.  Densification during Sintering in the Presence of a Liquid Phase. I. Theory , 1959 .

[117]  R. M. German,et al.  Critical use of video-imaging to rationalize computer sintering simulation models , 2005, Comput. Ind..

[118]  E. Watson,et al.  The distribution of partial melt in a granitic system: The application of liquid phase sintering theory , 1985 .

[119]  John L. Johnson,et al.  Finite Element Simulation of Liquid Phase Sintering with Tungsten Heavy Alloys , 2006 .

[120]  Y. Chiang,et al.  Effect of Initial Microstructure on Final Intergranular Phase Distribution in Liquid‐Phase‐Sintered Ceramics , 2004 .

[121]  Thomas A. Read,et al.  Physics of Powder Metallurgy , 1949 .

[122]  H. Kleebe,et al.  Core/Rim Structure of Liquid‐Phase‐Sintered Silicon Carbide , 1993 .

[123]  P. Voorhees,et al.  In situ observation of particle motion and diffusion interactions during coarsening , 1987 .

[124]  R. German Grain agglomeration in solid-liquid mixtures under microgravity conditions , 1995 .

[125]  A. Contreras,et al.  Interfacial phenomena in wettability of TiC by Al–Mg alloys , 2004 .

[126]  P. Pierre Constitution of Bone China: I, High‐Temperature Phase Equilibrium Studies in the System Tricalcium Phosphate—Alumina—Silica , 1954 .

[127]  Toshio Kimura,et al.  Effect of Bismuth of Oxide Content on the Sintering of Zinc Oxide , 1989 .

[128]  M. Sacks,et al.  Fabrication of Mullite and Mullite-Matrix Composites by Transient Viscous Sintering of Composite Powders , 1991 .

[129]  Interfacial reaction-controlled reprecipitation of W atoms in liquid matrix phase during the sintering of W-8 pct Mo-7 pct Ni-3 pct Fe , 1998 .

[130]  M. Drofenik,et al.  Release of Oxygen During the Sintering of Doped BaTiO3 Ceramics , 1982 .

[131]  Doh-Yeon Kim,et al.  Microstructural Evolution during the Sintering of TiC–Mo–Ni Cermets , 1993 .

[132]  R. Farr,et al.  Simulation of the microstructural evolution during liquid phase sintering using a geometrical Monte Carlo model , 2005 .

[133]  R. Warren,et al.  The contiguity of carbide crystals of different shapes in cemented carbides , 2006 .

[134]  R. German,et al.  Capillary forces between spheres during agglomeration and liquid phase sintering , 1987 .

[135]  R. German The contiguity of liquid phase sintered microstructures , 1985 .

[136]  D. Edmonds,et al.  Segregation to interphase boundaries in liquid-phase sintered tungsten alloys , 1983 .

[137]  Veena Tikare,et al.  Multi‐Scale Study of Sintering: A Review , 2006 .

[138]  A. Savitskii Liquid-Phase Sintering of the Systems With Interacting Components , 1999 .

[139]  H. Riedel,et al.  A LIQUID PHASE SINTERING MODEL: APPLICATION TO Si3N4 AND WC-Co , 1997 .

[140]  F. Massazza,et al.  Interaction Between Superplasticizers and Calcium Aluminate Hydrates , 1982 .

[141]  A. Niemi,et al.  Settling in solid-liquid systems with specific application to liquid phase sintering , 1983 .

[142]  J. Ågren,et al.  Rearrangement and pore size evolution during WC-Co sintering below the eutectic temperature , 2005 .

[143]  R. German,et al.  Contact angle and solid-liquid-vapor equilibrium , 1996 .

[144]  José M. Martínez-Esnaola,et al.  Simulation of liquid phase sintering using the Monte Carlo method , 2004 .

[145]  Wolfgang Haller,et al.  Rearrangement Kinetics of the Liquid—Liquid Immiscible Microphases in Alkali Borosilicate Melts , 1965 .

[146]  Po-Liang Liu,et al.  The K value distribution of liquid phase sintered microstructures , 2002 .

[147]  John L. Johnson,et al.  Role of solid-state skeletal sintering during processing of Mo-Cu composites , 2001 .

[148]  Torsten Kraft,et al.  Optimizing press tool shapes by numerical simulation of compaction and sintering—application to a hard metal cutting insert , 2003 .

[149]  Po-Liang Liu The relation between the distribution of dihedral angles and the wetting angle during liquid phase sintering , 2006 .

[150]  V. N. Eremenko,et al.  Liquid-Phase Sintering , 1995 .

[151]  D. Sciti,et al.  Effects of additives on densification, microstructure and properties of liquid-phase sintered silicon carbide , 2000 .

[152]  H. Nomura,et al.  Computational Design for Grain‐Oriented Microstructure of Functional Ceramics Prepared by Templated Grain Growth , 2006 .

[153]  J. Cahn,et al.  Analysis of Capillary Forces in Liquid‐Phase Sintering of Jagged Particles , 1970 .

[154]  K. Nogi,et al.  Critical Factors Affecting the Wettability of α‐Alumina by Molten Aluminum , 2004 .

[155]  G. Thomas,et al.  Microstructure of silicon nitride ceramics sintered with rare-earth oxides , 1995 .

[156]  Chung‐Hsin Lu,et al.  Influence of Nd2O3 Doping on the Reaction Process and Sintering Behavior of BaCeO3 Ceramics , 1994 .

[157]  D. Clarke,et al.  A thermodynamic approach to the wetting and dewetting of grain boundaries , 1997 .

[158]  H. Sohn,et al.  Mathematical modeling of liquid phase migration in solid-liquid mixtures: Application to the sintering of functionally graded WC-Co composites , 2007 .

[159]  Suk‐Joong L. Kang,et al.  Densification And Shrinkage During Liquid-Phase Sintering , 1991 .

[160]  T. Courtney Densification and structural development in liquid phase sintering , 1984 .

[161]  C. Rado,et al.  Mechanisms of reactive wetting: the wetting to non-wetting case , 1999 .

[162]  N. Xydas,et al.  Transient liquid phase sintering of high density Fe3Al using Fe and Fe2Al5–FeAl2 powders Part 2 – Densification mechanism analysis , 2006 .

[163]  Seong-Jai Cho,et al.  Pore filling process in liquid phase sintering , 1984 .

[164]  M. B. Waldron,et al.  MICROSTRUCTURAL DEVELOPMENT DURING THE LIQUID-PHASE SINTERING OF CEMENTED CARBIDES , 1972 .

[165]  T. Courtney A reanalysis of the kinetics of neck growth during liquid phase sintering , 1977 .

[166]  P. Wray The geometry of two-phase aggregates in which the shape of the second phase is determined by its dihedral angle , 1976 .

[167]  T. Tanase Some Phenomena in Submicro-Grained WC-Co Cemented Carbide , 2006 .

[168]  E. Ising Beitrag zur Theorie des Ferromagnetismus , 1925 .

[169]  D. Milner,et al.  Densification Mechanisms in the Tungsten Carbide—Cobalt System , 1976 .

[170]  R. German Microstructure of the gravitationally settled region in a liquid-phase sintered dilute tungsten heavy alloy , 1995 .

[171]  L. Kozma,et al.  Initiation of Directional Grain Growth During Liquid-Phase Sintering of Tungsten and Nickel , 1981 .

[172]  R. German Manipulation of Strength During Sintering as a Basis for Obtaining Rapid Densification without Distortion , 2001 .