Plasma-assisted sintering

Abstract

Methods and systems for plasma-assisted sintering are provided. The method can include initiating a sintering plasma with a cavity (12) by subjecting a gas to radiation in the presence of a plasma catalyst and exposing at least a portion of an object which can be a powdered material component to the plasma for a period of time sufficient to sinter at least a portion of the object.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] Priority is claimed to U.S. Provisional Patent Application No. 60 / 378,693, filed May 8, 2002, No. 60 / 430,677, filed Dec. 4, 2002, and No. 60 / 435,278, filed Dec. 23, 2002, all of which are fully incorporated herein by reference.FIELD OF THE INVENTION [0002] This invention relates to sintering systems and methods. More specifically, the invention relates to systems and methods for igniting, modulating, and sustaining plasmas from gases using electromagnetic radiation in the presence of plasma catalysts and for using the plasmas in sintering processes. BACKGROUND [0003] Various sintering methods are known. These methods can involve the thermal treatment of a powder at a temperature below its melting point. This thermal treatment can bond the powder particles together to increase the strength of the resulting sintered material. [0004] Prior to some sintering processes, for example, the powder (e.g., a metal, ceramic, or other) can be compre...

AI Technical Summary

Problems solved by technology

It may difficult, however, to precisely control the temperature of the material using these furnaces.

This lag may be significant, and in certain sintering processes, not all of the material to be sintered may achieve a desired processing temperature or satisfy a desired time-temperature profile.

This can lead to incomplete sintering of the material, and as a result, the sintered material may be less dense than predicted or desired.

Further, some sintering methods using conventional furnaces may not be suited for sintering objects with non-standard profiles or shapes, such as, for example, reentrant features, multiple thicknesses, thin or small features, and variable cross sections.

Moreover, atmospheric sintering furnaces may be slow in heating and may lack the ability to precisely control the temperature of the object.

While plasma sintering methods may offer potential increases in heating rates over traditional furnace sintering methods, these plasma sintering methods normally involve the use of costly vacuum equipment.

Images