Spark Plasma Sintering Laboratory

Scientific results:

• Our researchers have studied the influence of electric current (field) on the growth of grains of materials, the speeds of compaction and deformation of ceramic, metal and ceramic-metal materials and nanocomposites (we have studied materials conducting electric current and insulator materials).
• The Laboratory has developed a methodology and equipment for the integral control of of the technological process in a spark plasma sintering (SPS) system. The temperature in the sintering zone and the compressive force were chosen as controlled parameters. Eight patents for devices for producing items based on composite powders have been obtained.
• We have developed software that allows to model temperature fields accounting for the properties and geometry of the matrix and the sample on the basis of the mathematical models and microphysical description of the process that has been developed by the Laboratory. Thanks to this software it is possible to determine the necessary technological  parameters of the process of hybrid spark plasma sintering (the maximum temperature and the speed of heating of powder compact, the duration and shape of the impulse, the applied pressure).
• We have developed technologies for producing innovative nonporous nanocomposites ceramic materials with enhanced operational properties based on the systems: WC, Al₂O₃-ZrO₂-TiN, Si₃N₄, TiC, Al₂O₃-SiCw-TiC and Al₂O₃-SiCw. The volume content of pores is less than 0,01 per cent; the grain size does not exceed 500 nn; the crack resistance is more than 13,24 MPa·m^1/2. On the basis of the results of this work we have published a number of scientific articles and patents have been obtained for results of intellectual activity.
• Our researchers have conducted works that encompass all the stages of the production of new materials by spark plasma sintering: modeling the process of spark plasma sintering, preparing mixtures of nanopowders, studying the properties of the produced mixtures of powders, sintering of materials, studying the properties of the produced samples.
• We have developed step-by-step methodologies for producing a new class of nanocomposite gradient materials for the machine building industry with enhanced properties.
• The Laboratory has developed technologies for producing nonporous nanocomposite  ceramic materials with an enhanced complex of operational properties modified with carbon nanofibers and graphene. Patents for inventions have been acquired on the basis of the results of this work.
• Our team has developed a technology for producing a nanocomposite on the basis of copper by spark plasma sintering and mechanical doping that is able to replace silver in interrupting electrical contacts with minimum technological losses of the source material. This technology allows to manufacture contacts without additional processing (unlike the extrusion technology). The material has a temperature of  unhardening exceeding 850°С and does not swell during exposure to temperatures higher than 850°С, its specific electric conductivity reaches 48,3 MS/m (83% IACS).
• We have developed technologies for producing ceramic and metal ceramic metal nanocomposite products of complex geometric shapes. By optimizing the technological parameters of the process of hybrid spark plasma sintering and using a specially designed graphite tooling we have managed to achieve high values of the mechanical properties as well as to ensure their uniform distribution over the volume of sintered  ceramic nanocomposites of square cross section.

Implemented results of research:

• Employees of the Laboratory have been conducting work and providing scientific and technological services to external contractors. The works include: preparing powder materials and compositions, the molding and compaction of powder materials, the sintering of materials, the thermal processing of materials and products, the research of the properties of  materials (determining the physical, mechanical and thermal properties and the chemical composition). Contracts for performing R&D have been signed with JSC NIITFA, the State Institute of Drugs and Good Practices, JSC Ryazan Design Bureau «Globus» and others.
• The technology for the spark plasma sintering of graphene-reinforced nanocomposite materials with an improved complex of mechanical and operational characteristics have been used to produce replaceable multifaceted cutting plates by OJSC «VNIIINSTRUMENT».

Education and career development:

• The following lecture courses have been included in the educational process of the university: «Instrumental provision of machinery manufacture», «Nanotechnologies in machinery manufacture», «Efficiency of processing methods», «Technological foundations of high-speed shape-forming processing of materials», «Materials and highly efficient technologies of modern manufacturing», «Modern materials of the machine building industry», «Intensification of processing», «Introduction to nanotechnologies».
• Internships have been organized at leading foreign science and education centers, universities and top industrial organizations such as the Spanish Nanomaterials and Nanotechnology Research Center (CINN), the Polytechnic University of Milan (Italy), the University of Zielona Góra (Poland), FCT Systeme GmbH (Germany), that manufacture heat pressing equipment, spark plasma sintering facilities.
• Two bachelor's degree theses, two  master's theses and two Candidate of Sciences dissertations have been prepared and defended.

Organizational and structural changes:

Since 2022, the Laboratory has been a part of the Center for New Materials and Technologies of the State engineering center of MSTU «STANKIN».

Other results:

• A Russian Science Foundation grant for conducting R&D, topic «Development of scientific principles and innovative technologies based on plasma processes for the manufacturing of products with controlled adaptive reaction to external impact for application in mechanical processing, functional nodes of machines and devices», implemented in 2021 – 2024.
• A grant for conducting fundamental scientific research and surveying scientific research  topic «Development of scientific principles and innovative technologies based on plasma processes for the manufacturing of products with controlled adaptive reaction to external impact for application in mechanical processing, functional nodes of machines and devices», implemented in 2021 – 2024.
• A Russian Science Foundation grant, topic «Developing a technology for producing graphene-doped ceramic pastes and nanostructured ceramic products of complex spatial configurations», implemented in  2019 – 2021.
• An R&D project within the implementation of the Decree No. 218 of the Government of the Russian Federation «Development and organization of a high-tech production of innovative complexes for electric heating for cross-industry use with breakthrough operational characteristics», implemented in 2017-2020.
• Federal Targeted Program for Research and Development in Priority Areas of Advancement of the Russian Scientific and Technological Complex for 2014-2020, topic: «Development of a technology of the electrochemical deposition  of ceramic-like reinforcement coatings onto complex-profile surfaces of devices made of valve metals», implemented in 2018-2020.
• Federal Targeted Programme for Research and Development in Priority Areas of Advancement of the Russian Scientific and Technological Complex for 2014-2020, topic: «Development of high-performance antifriction aluminum alloys, technologies of their production and monometallic slide bearings from those that can work in conditions of liquid and boundary friction», implemented in 2017-2019.

Collaborations:

• Materials Science Institute of Madrid (Spain): research of the tribological behavior of ceramic metal composites based on zirconium oxide with addition of tantalum, research of the influence of the parameters of electroerosion processing on the properties of ceramic metal composites based on zirconium oxide with the addition of tantalum, the second workshop on processing and manufacturing of new ceramic materials (10-13 April 2018), joint research of ceramic metal composites based on zirconium oxide reinforced with tantalum with and without the addition of graphene oxide, research of  the tribological behavior of ceramic nanocomposites based on aluminum oxide reinforced with silicon carbide fibers with the addition of graphene, research of the impact of the parameters of electroerosion processing on the strength of ceramic nanocomposites based on zirconium oxide with titanium nitride.
• «SpetsDizelServis» Ltd (Russia): development of recommendations for the optimization of the compositions of experimental antifrictional bearing alloys based on aluminum according to results of mechanical, tribological testing and research of the friction surfaces. For the fist time the development of antifriction materials was conducted  not on the basis of the improvement of the mechanical, conductivity and tribological properties of a material but on the basis of the results of a research of structures  formed on the friction surfaces; new antifriction materials on the basis of aluminum that are able to replace costly bronzes in monometallic slide bearings for operating in various friction conditions that rule out kink in a steel counterbody in case of tear by the Rehbinder effect. A technology has been developed for producing monometallic bearings from new aluminum-based alloys. Experimental samples of monometallic slide bearings have been produced on the basis of the developed multicomponent aluminum alloy.
• «SSTenergomontazh» Ltd. (Russia): development and organization of a high-tech production of innovative complexes of electric heating for cross-industry use. With breakthrough operational characteristics.
• «Mirrico management» (Russia): design and encapsulation of a pilot batch of  natrium percarbonate powder by polymer deposition.
• «EKOS-1» JSC (Russia): production of a pilot batch of f-liquidized layer liquidator,samples made of zirconium dioxide, producing samples of ceramic materials by spark plasma sintering.
• Institute for Nuclear Research of the Russian Academy of Sciences: R&D for the production of disks from metallic chrome manufactured by spark plasma sintering.
• «Mosavtosteklo» Ltd (Russia): production of samples by cold isostatic pressing with subsequent high-temperature vacuum furnace followed by control of the physical and mechanical and physical characteristics.
• State Institute of Drugs and Good Practices (Russia): accumulation of laboratory lots of granulates of pharmaceuticals using a pseudo-liquidized layer, conducting scientific and technological works to develop pilot lots of pharmaceuticals covered  with a polymer coating.
• Research Institute of Technical Physics and Automation (Russia): developing a method for designing a nanostructured thermoelectric material based on solid solutions  of bismuth chalcogenides and antimony by spark plasma sintering.
• Ryazan Design Bureau «Globus» JSC (Russia): development of a technology for applying ceramic-like coatings to valve metals, design and manufacturing of a prootype of a device for applying ceramic-like coatings, producing experimental samples, conducting operational testing of experimental samples.
• «VNIIZhT» JSC (Russia): research in the field of the production of new materials for railway transport, the creation of a nanocomposite on the basis of copper to replace silver in  interrupting electric contacts (Cu-Al₂O₃) as well as new antifriction aluminum   materials for monometallic slide bearings.
• «VNIIINSTRUMENT» JSC (Russia): research in the field of the production of new  materials for cutting instruments, the creation of nanostructured ceramic materials for the production of replaceable multifaceted cutting blades with an improved complex of properties.
• Autonomous University of Madrid (Spain): research in the field of creation of ceramic biostructured nanocomposites, creation of a new failsafe and wear-resistant composite based on zirconium oxide and tantalum for applications in heavy-duty products.
• Friedrich Schiller University Jena (Germany): research in the field of creation of new   compositions of materials, creation of a new ceramic nanocomposite from powders produced using the LAVA (Laser evaporation method) method.
• Spanish Nanomaterials and Nanotechnology Research Center (CINN) (Spain): production of new ceramic composites (Al₂O₃-SiCw-TiC, 3Y–TZP/rGO, TiCN-NbCN-TaCN, ZrO₂-Ni and other similar compounds) with an increased complex of mechanical and physical properties.
• Institute of Strength Physics and Materials Science of the Siberian Branch of the Russian Academy of Sciences (Russia): developing a new biocomposite with bactericidal and good osseointegration properties.
• «World Market» Ltd. (Russia): creation of new powder compositions.
• «Nanoker Research» Ltd. (Spain): research in the field of ceramic next-generation cutting tools, creating nanostructured ceramic materials Al₂O₃-SiCw-TiC-Ni.