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This work addresses the two great challenges of the spark plasma sintering(SPS) process: the sintering of complex shapes and the simultaneous productionof multiple parts. A new controllable interface method is employed toconcurrently consolidate two nickel gear shapes by SPS. A graphite deformablesub-mold is specifically designed for the mutual densification of the bothcomplex parts in a unique 40 mm powder deformation space. An energy efficientSPS configuration is developed to allow the sintering of a large-scale powderassembly under electric current lower than 900 A. The stability of thedeveloped process is studied by electro-thermal-mechanical (ETM) simulation.The ETM simulation reveals that homogeneous densification conditions can beattained by inserting an alumina powder at the sample/punches interfacesenabling the energy efficient heating and the thermal confinement of the nickelpowder. Finally, the feasibility of the fabrication of the two near net shapegears with a very homogeneous microstructure is demonstrated.

Simultaneous Spark Plasma Sintering of Multiple Complex Shapes