Is this project an undergraduate, graduate, or faculty project?
Undergraduate
Project Type
individual
Campus
Daytona Beach
Authors' Class Standing
Harshail Patet, Junior
Lead Presenter's Name
Harshail Patet
Lead Presenter's College
DB College of Engineering
Faculty Mentor Name
RAGHAVS3@erau.edu
Abstract
Alumina is one of the most widely used advanced ceramics, serving applications that range from dense structural and wear-resistant components to porous thermal insulation and filtration systems. Porosity is a defining microstructural feature that governs mechanical strength, thermal conductivity, and permeability, meaning different applications demand different porosity levels from the same material. Spark plasma sintering (SPS) enables rapid consolidation by simultaneously applying pulsed electric current and uniaxial pressure, offering precise control over density, grain size, and porosity in significantly shorter processing times than conventional sintering. While prior studies have investigated the individual effects of SPS parameters on alumina densification, a systematic processing window linking specific parameter combinations to discrete, reproducible porosity levels has not yet been established. Here, we develop an SPS parameter map for alumina that targets different porosity levels by systematically varying sintering temperature, applied pressure, and hold time. By isolating each parameter, we demonstrate that increasing temperature, pressure, and hold time accelerate densification by influencing the sample's microstructural evolution. Densification is verified through geometric measurements, density testing per ASTM C373 following Archimedes' principle, and SEM analysis of fracture surfaces. These results establish a repeatable, process-driven approach to engineering porosity in SPS-processed alumina, providing a practical roadmap for tailoring microstructure to application-specific requirements
Did this research project receive funding support (Spark, SURF, Research Abroad, Student Internal Grants, Collaborative, Climbing, or Ignite Grants) from the Office of Undergraduate Research?
No
Included in
Spark Plasma Sintering of alumina with controlled porosity
Alumina is one of the most widely used advanced ceramics, serving applications that range from dense structural and wear-resistant components to porous thermal insulation and filtration systems. Porosity is a defining microstructural feature that governs mechanical strength, thermal conductivity, and permeability, meaning different applications demand different porosity levels from the same material. Spark plasma sintering (SPS) enables rapid consolidation by simultaneously applying pulsed electric current and uniaxial pressure, offering precise control over density, grain size, and porosity in significantly shorter processing times than conventional sintering. While prior studies have investigated the individual effects of SPS parameters on alumina densification, a systematic processing window linking specific parameter combinations to discrete, reproducible porosity levels has not yet been established. Here, we develop an SPS parameter map for alumina that targets different porosity levels by systematically varying sintering temperature, applied pressure, and hold time. By isolating each parameter, we demonstrate that increasing temperature, pressure, and hold time accelerate densification by influencing the sample's microstructural evolution. Densification is verified through geometric measurements, density testing per ASTM C373 following Archimedes' principle, and SEM analysis of fracture surfaces. These results establish a repeatable, process-driven approach to engineering porosity in SPS-processed alumina, providing a practical roadmap for tailoring microstructure to application-specific requirements