FEM analysis of the temperature and stress distribution in spark plasma sintering: Modelling and experimental validation

A fully thermal–electrical–mechanical coupled and dynamic finite element model (FEM) is implemented to analyze of the temperature and stress distribution in spark plasma sintering (SPS) process. The real densification behaviour is also integrated by the moving mesh technique. The simulation studies were conducted using COMSOL and a range of die sizes, heating rates and uniaxial stresses were considered. The further validation experiments are implemented to validate the simulation results. The detailed microstructure investigations generally demonstrate that the temperature and stress profile obtained in present model are correct. But further development of complicated models is still needed for more precise prediction of sintering condition and microstructure development in SPS.