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Simulation of Sintering of Layered Structures

Description: An integrated approach, combining the continuum theory of sintering and Potts model based mesostructure evolution analysis, is used to solve the problem of bi-layered structure sintering. Two types of bi-layered structures are considered: layers of the same material with different initial porosity, and layers of two different materials. The effective sintering stress for the bi-layer powder sintering is derived, both at the meso- and the macroscopic levels. Macroscopic shape distortions and spatial distributions of porosity are determined as functions of the dimensionless specific time of sintering. The effect of the thickness of the layers on shrinkage, warpage, and pore-grain structure is studied. Ceramic ZnO powders are employed as a model experimental system to assess the model predictions.
Date: November 22, 2000
Partner: UNT Libraries Government Documents Department

Combined macro-meso scale modeling of sintering. Part II, Mesoscale simulations

Description: A mesoscale kinetic Monte Carlo model is presented to simulate microstructural evolution during sintering of 2D complex microstructures which evolves by grain growth, pore migration and densification. No assumptions about the geometry of the evolving microstructure are made. The results of these simulations are used to generate sintering stress and normalize viscous bulk modulus for use in continuum level simulation of sintering. The advantage of these simulations is that they can be used to generate more accurate parameters as various assumptions regarding geometry and transport mechanism are made. The previous companion paper used the results from the mesoscale simulations to simulate shrinkage and warpage in sintering of bilayer ceramics.
Date: May 23, 2000
Partner: UNT Libraries Government Documents Department

A Combined Statistical-Microstructural Model for Simulation of Sintering

Description: Sintering theory has been developed either as the application of complex diffusion mechanisms to a simple geometry or as the deformation and shrinkage of a continuum body. They present a model that can treat in detail both the evolution of microstructure and the sintering mechanisms, on the mesoscale, so that constitutive equations with detail microstructural information can be generated. The model is capable of simulating vacancy diffusion by grain boundary diffusion, annihilation of vacancies at grain boundaries resulting in densification, and coarsening of the microstructural features. In this paper, they review the stereological theory of sintering and its application to microstructural evolution and the diffusion mechanism, which lead to sintering. They then demonstrate how these stereological concepts and diffusion mechanisms were incorporated into a kinetic Monte Carlo model to simulate sintering. Finally, they discuss the limitations of this model.
Date: October 22, 1999
Partner: UNT Libraries Government Documents Department

On the Connection Between the Discrete Dislocation Slip Model and the Orowan Equation

Description: Within the framework of thermodynamic theory of plasticity and specific structural-variables (associated with individual dislocations), a transition has been made to an expression containing one internal variable of the averaging type--the density of glissile dislocations, N{sub g}. This expression should be considered a tensorial generalization of the well-known Orowan's equation and relates it directly to the simplest possible case of normal flow in metallic materials. Since most metals display deviations from normality in the flow rule{sup 7} it also clearly indicates that more rigorous assessment of the relation between plastic strain rate and dislocation populations is required especially for materials displaying plastic instabilities in the form of dislocation patterning, strain-softening and strain-rate softening phenomena. The obtained result could be a useful starting point in establishing such rigorous macroscopic relations from microscopic considerations associated with individual dislocations and to find useful applications in dislocation density-related constitutive modeling of plastic deformation.
Date: September 8, 1999
Creator: Braginsky, Michael V.; Glazov, Michael V. & Richmond, Owen
Partner: UNT Libraries Government Documents Department

Microstructural and continuum evolution modeling of sintering.

Description: All ceramics and powder metals, including the ceramics components that Sandia uses in critical weapons components such as PZT voltage bars and current stacks, multi-layer ceramic MET's, ahmindmolybdenum & alumina cermets, and ZnO varistors, are manufactured by sintering. Sintering is a critical, possibly the most important, processing step during manufacturing of ceramics. The microstructural evolution, the macroscopic shrinkage, and shape distortions during sintering will control the engineering performance of the resulting ceramic component. Yet, modeling and prediction of sintering behavior is in its infancy, lagging far behind the other manufacturing models, such as powder synthesis and powder compaction models, and behind models that predict engineering properties and reliability. In this project, we developed a model that was capable of simulating microstructural evolution during sintering, providing constitutive equations for macroscale simulation of shrinkage and distortion during sintering. And we developed macroscale sintering simulation capability in JAS3D. The mesoscale model can simulate microstructural evolution in a complex powder compact of hundreds or even thousands of particles of arbitrary shape and size by 1. curvature-driven grain growth, 2. pore migration and coalescence by surface diffusion, 3. vacancy formation, grain boundary diffusion and annihilation. This model was validated by comparing predictions of the simulation to analytical predictions for simple geometries. The model was then used to simulate sintering in complex powder compacts. Sintering stress and materials viscous module were obtained from the simulations. These constitutive equations were then used by macroscopic simulations for simulating shrinkage and shape changes in FEM simulations. The continuum theory of sintering embodied in the constitutive description of Skorohod and Olevsky was combined with results from microstructure evolution simulations to model shrinkage and deformation during. The continuum portion is based on a finite element formulation that allows 3D components to be modeled using SNL's nonlinear large-deformation finite element code, JAS3D. ...
Date: December 1, 2003
Creator: Braginsky, Michael V.; Olevsky, Eugene A. (San Diego State University, San Diego, CA); Johnson, D. Lynn (Northwest University, Evanston, IL); Tikare, Veena; Garino, Terry J. & Arguello, Jose Guadalupe, Jr.
Partner: UNT Libraries Government Documents Department