COMPLAS 2025

Multiphysics Discrete-Element Modelling of Electric-Current-Assisted Sintering

  • Rojek, Jerzy (IPPT PAN)
  • Nisar, Fatima (IPPT PAN)
  • Nosewicz, Szymon (IPPT PAN)
  • Chmielewski, Marcin (Lukasiewicz-IMIF)
  • Kaszyca, Kamil (Lukasiewicz-IMIF)

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Electric-current-assisted sintering (ECAS), also called spark plasma sintering (SPS), is a powder metallurgy process that employs electric current to generate heat (Joule effect) while simultaneously applying pressure to achieve consolidation and densification of particulate material. The complexity of the process stems from the interdependence of electrical, thermal and mechanical phenomena. Modelling this complex process requires a multiphysics approach that combines electrical, thermal, and mechanical problems. In this work, a coupled microscopic thermo-electric-mechanical model is developed within the discrete element framework. In the discrete element method (DEM), spherical discrete elements represent powder particles, which makes the DEM a suitable tool for micromechanical modelling of the ECAS process. The model is based on the sintering geometry, which assumes a cylindrical neck connection between particles. Additional thermal and electrical resistance is introduced at the neck. In the development of the model, first, each physical phenomenon was addressed separately and then combined to build a complete coupled model. The DEM model was used to simulate thermal and electrical conduction and evaluate the effective properties of partially sintered porous material with a heterogeneous microstructure [1,2]. Then, the DEM model was applied to model electro-mechanical, thermo-electric and fully coupled thermo-electric-mechanical phenomena in ECAS processes. Numerical results were compared with own experimental data.