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A new sintering method, namely ultrasonic assisted sintering (UAS), has been proposed using mechanical heat converted from high frequency motion between particles. Pure aluminum specimens with diameter of 5 mm and thickness of ~2 mm have been successfully sintered in two seconds. Based on the thermodynamic analysis, the underlying heating mechanism is quantitatively interpreted, which involves high-frequency interparticle friction and plastic deformation driven by ultrasonic squeezing. Consequently, temperature rises rapidly at a speed of about 300 K/s, and the maximum temperature reaches up to 0.9 times of melting point of the aluminum during UAS. The sintered specimens have a high density of dislocations, under the combined effects of dislocations and undulating stress field, volume diffusion coefficient for sintering increases by several orders of magnitude, therefore, rapid densification can be accomplished in seconds. In addition, the sintered aluminum has ultrahigh nanohardness (~1.13 GPa), which can be attributed to the hierarchical structure formed during UAS process.

Ultrasonic Assisted Sintering Using Heat Converted from Mechanical Energy