Spark‐plasma sintering (SPS) has the potential for rapid (with heating rates reaching several hundred K/min) and efficient consolidation of a broad spectrum of powder materials. Possible mechanisms of the enhancement of consolidation in SPS versus conventional techniques of powder processing are categorized with respect to their thermal and athermal nature. This paper analyzes the influence of thermal diffusion, which is an SPS consolidation enhancement factor of a thermal nature. The Ludwig–Soret effect of thermal diffusion causes concentration gradients in two‐component systems subjected to a temperature gradient. The thermal diffusion‐based constitutive mechanism of sintering results from the additional driving force instigated by spatial temperature gradients, which cause vacancy diffusion. This mechanism is a commonly omitted addition to the free‐surface curvature‐driven diffusion considered in conventional sintering theories. The interplay of three mechanisms of material transport during SPS is considered: surface tension‐ and external stress‐driven grain‐boundary diffusion, surface tension‐ and external stress‐driven power‐law creep, and temperature gradient‐driven thermal diffusion. It is shown that the effect of thermal diffusion can be significant for ceramic powder systems. Besides SPS, the results obtained are applicable to the ample range of powder consolidation techniques, which involve high local temperature gradients. The case study conducted on the alumina powder SPS demonstrates the correlation between the modeling and experimental data. It is noted that this study considers only one of many possible mechanisms of the consolidation enhancement during SPS. Further efforts on the modeling of field‐assisted powder processing are necessary.

Spark plasma sintering (SPS), a sintering method that uses the action of pulsed direct current and pressure, has received a lot of attention due to its capability of exerting control over the microstructure of the sintered material and flexibility in terms of the heating rate and heating mode. Historically, SPS was developed in search of ways to preserve a fine-grained structure of the sintered material while eliminating porosity and reaching a high relative density. These goals have, therefore, been pursued in the majority of studies on the behavior of materials during SPS. Recently, the potential of SPS for the fabrication of porous materials has been recognized. This article is the first review to focus on the achievements in this area. The major approaches to the formation of porous materials by SPS are described: partial densification of powders (under low pressures, in pressureless sintering processes or at low temperatures), sintering of hollow particles/spheres, sintering of porous particles, and sintering with removable space holders or pore formers. In the case of conductive materials processed by SPS using the first approach, the formation of inter-particle contacts may be associated with local melting and non-conventional mechanisms of mass transfer. Studies of the morphology and microstructure of the inter-particle contacts as well as modeling of the processes occurring at the inter-particle contacts help gain insights into the physics of the initial stage of SPS. For pre-consolidated specimens, an SPS device can be used as a furnace to heat the materials at a high rate, which can also be beneficial for controlling the formation of porous structures. In sintering with space holders, SPS processing allows controlling the structure of the pore walls. In this article, using the literature data and our own research results, we have discussed the formation and structure of porous metals, intermetallics, ceramics, and carbon materials obtained by SPS.

A new flash (ultra-rapid) spark plasma sintering method applicable to various materials systems, regardless of their electrical resistivity, is developed. A number of powders ranging from metals to electrically insulative ceramics have been successfully densified resulting in homogeneous microstructures within sintering times of 8–35 s. A finite element simulation reveals that the developed method, providing an extraordinary fast and homogeneous heating concentrated in the sample’s volume and punches, is applicable to all the different samples tested. The utilized uniquely controllable flash phenomenon is enabled by the combination of the electric current concentration around the sample and the confinement of the heat generated in this area by the lateral thermal contact resistance. The presented new method allows: extending flash sintering to nearly all materials, controlling sample shape by an added graphite die, and an energy efficient mass production of small and intermediate size objects. This approach represents also a potential venue for future investigations of flash sintering of complex shapes.