Multi‐Scale Study of Sintering: A Review

An integrated approach, combining the continuum theory of sintering with a kinetic Monte-Carlo (KMC) model-based mesostructure evolution simulation is reviewed. The effective sintering stress and the normalized bulk viscosity are derived from mesoscale simulations. A KMC model is presented to simulate microstructural evolution during sintering of complex microstructures taking into consideration grain growth, pore migration, and densification. The results of these simulations are used to generate sintering stress and normalized bulk viscosity for use in continuum level simulation of sintering. The advantage of these simulations is that they can be employed to generate more accurate constitutive parameters based on most general assumptions regarding mesostructure geometry and transport mechanisms of sintering. These constitutive parameters are used as input data for the continuum simulation of the sintering of powder bilayers. Two types of bilayered structures are considered: layers of the same particle material but with different initial porosity, and layers of two different materials. The simulation results are verified by comparing them with shrinkage and warping during the sintering of bilayer ZnO powder compacts.

[1]  J. Svoboda,et al.  Equilibrium pore surfaces, sintering stresses and constitutive equations for the intermediate and late stages of sintering—II. Diffusional densification and creep , 1994 .

[2]  Jeffrey W. Bullard,et al.  Digital-image-based models of two-dimensional microstructural evolution by surface diffusion and vapor transport , 1997 .

[3]  J. Schneibel,et al.  The sintering of two particles by surface and grain boundary diffusion -- A two-dimensional numerical study , 1995 .

[4]  E. Olevsky,et al.  HIPing conditions for processing of metal matrix composites using the continuum theory for sintering—I. Theoretical analysis , 1996 .

[5]  M. Harmer,et al.  Effect of Pore Distribution on Microstructure Development: I, Matrix Pores , 1988 .

[6]  M. Ashby,et al.  A second report on sintering diagrams , 1981 .

[7]  H. Exner.  Neck shape and limiting GBDSD ratios in solid state sintering , 1987 .

[8]  H. Riedel,et al.  Equilibrium pore surfaces, sintering stresses and constitutive equations for the intermediate and late stages of sintering—I. computation of equilibrium surfaces , 1994 .

[9]  R. Balluffi,et al.  The mechanism of sintering of copper , 1957 .

[10]  W. Kingery,et al.  Study of the Initial Stages of Sintering Solids by Viscous Flow, Evaporation‐Condensation, and Self‐Diffusion , 1955 .

[11]  Anand Jagota,et al.  Micromechanical modeling of powder compacts—I. Unit problems for sintering and traction induced deformation , 1988 .

[12]  Denis Weaire,et al.  Monte Carlo simulation of the evolution of a two-dimensional soap froth , 1986 .

[13]  S. Bordère.  Original Monte Carlo Methodology Devoted to the Study of Sintering Processes , 2004 .

[14]  Rajiv K. Kalia,et al.  Early stages of sintering of silicon nitride nanoclusters: a molecular-dynamics study on parallel machines , 1996 .

[15]  F. Nichols.  Coalescence of Two Spheres by Surface Diffusion , 1966 .

[16]  E. Olevsky,et al.  Numerical Simulation of Anisotropic Shrinkage in a 2D Compact of Elongated Particles , 2004 .

[17]  D. Johnson,et al.  Diffusion Sintering: I, Initial Stage Sintering Models and Their Application to Shrinkage of Powder Compacts , 1963 .

[18]  P. C. Clapp,et al.  Nanoparticle sintering simulations , 1998 .

[19]  E. Olevsky,et al.  Instability of sintering of porous bodies , 2000 .

[20]  P. S. Sahni,et al.  Computer simulation of grain growth—I. Kinetics , 1984 .

[21]  F. A. Nichols,et al.  Morphological Changes of a Surface of Revolution due to Capillarity‐Induced Surface Diffusion , 1965 .

[22]  Veena Tikare,et al.  Numerical simulation of solid state sintering , 2005 .

[23]  Robert L. Coble,et al.  Initial Sintering of Alumina and Hematite , 1958 .

[24]  I-Wei Chen,et al.  Computer Simulation of Final‐Stage Sintering: I, Model Kinetics, and Microstructure , 1990 .

[25]  David J. Srolovitz,et al.  Computer simulation of recrystallization-I. Homogeneous nucleation and growth , 1986 .

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

[27]  Robert M. McMeeking,et al.  Deformation of Interparticle Necks by Diffusion-Controlled Creep , 2005 .

[28]  E. Olevsky,et al.  Effect of gravity on dimensional change during sintering—I. Shrinkage anisotropy , 2000 .

[29]  G. Messing,et al.  Residual stresses in alumina–zirconia laminates , 1999 .

[30]  R. German,et al.  Simulation of spherical powder sintering by surface diffusion , 1978 .

[31]  D. Johnson,et al.  Grain boundary and volume diffusion in the sintering of silver , 1964 .

[32]  V. Tikare,et al.  Simulation of Grain Growth and Pore Migration in a Thermal Gradient , 2005 .

[33]  Eugene A. Olevsky,et al.  Theory of sintering: from discrete to continuum , 1998 .

[34]  V. Tikare,et al.  Modelling of anisotropic sintering in crystalline ceramics , 2005 .

[35]  E. Olevsky,et al.  Hiping conditions for processing of metal matrix composites using continuum theory for sintering—II. Application to fibre reinforced titanium alloys , 1996 .

[36]  G. Messing,et al.  Warpage Evolution of Screen Printed Multilayer Ceramics during Co-Firing , 2004 .

[37]  G. Grest,et al.  Effects of lattice anisotropy and temperature on domain growth in the two-dimensional Potts model. , 1991, Physical review. A, Atomic, molecular, and optical physics.

[38]  D. Johnson,et al.  New Method of Obtaining Volume, Grain‐Boundary, and Surface Diffusion Coefficients from Sintering Data , 1969 .

[39]  T. Ikegami.  Microstructural development during intermediate- and final-stage sintering , 1987 .