Rapid discharge sintering of nickel–diamond metal matrix composites

In this study rapid discharge sintering (RDS) and furnace sintering of nickel–diamond metal matrix composites (MMCs) is compared. Nickel–diamond powder composites (80–20% by weight respectively) were uniaxially pressed into 20 mm discs at compaction pressures of 100, 200 and 300 MPa. Discharge sintering was carried out using a microwave plasma formed with hydrogen and hydrogen/nitrogen as the discharge gases and tube furnace sintering carried out in a argon or a hydrogen/nitrogen (3:1) atmosphere. Discs pressed to 300 MPa were treated at both 850 and 1000 °C. The properties of the sintered nickel–diamond composites were characterized using density, approximate flexural strength, hardness, wear resistance, scanning electron microscopy (SEM) and X-ray diffraction (XRD). The RDS samples sintered at 1000 °C achieved the maximum approximate disc flexural strength of 473 MPa within a 20 min treatment time compared with 6 h for furnace sintered samples. Samples sintered using the RDS technique exhibited increased hardness values and a finer nickel matrix over furnace sintered samples. Using the RDS technique it has been possible to process nickel–diamond MMCs without oxidation or graphitisation at temperatures above 900 °C. Minimal diamond destruction was observed during abrasive wear testing of the RDS samples compared with damage and pull-out observed for furnace sintering.

► A novel rapid discharge sintering technology has been developed.
► Metal matrix composites have been sintered successfully.
► Rapid processing was carried in 20 min compared with 6 h using conventional methods.
► Comparable density, hardness and strength was observed compared with tube furnace sintering.
► No degradation of diamond particles has been found above 1000 °C.