Optimizing flash sintering outcomes using response surface methodology

Author(s)

Fábulo Ribeiro Monteiro ^[1] ; João Vitor Campos ^[2] ; Gustavo César Dacanal ; Lilian Menezes Jesus ^[4] ; Adilson Luiz Chinelatto ^[5] ; Eliria Maria de Jesus Agnolon Pallone ; Rafael Vieira de Sousa ^[7]

Affiliation

^[1] University of São Paulo. FZEA - Brasil

^[2] Federal University of São Carlos. Center for Research, Technology and Education in Vitreous Materials. Department of Materials Engineering - Brasil

^[4] Federal University of de São Carlos. Department of Physics - Brasil

^[5] State University of Ponta Grossa. Department of Materials Engineering - Brasil

^[7] University of São Paulo. FZEA. Department of Biosystems Engineering - Brasil

• Document type: Journal article
• Source: Cerâmica; v. 71, 2025-02-28.

Abstract

Abstract Flash sintering, renowned for its rapid densification of ceramic materials, lacks comprehensive studies on the influence of electric field and current density on densification due to potential variations based on furnace type and sample geometry. This study introduces a computational modeling technique using response surface methodology to predict densification, onset temperature, and steady-state temperature in flash sintering. A mathematical model was developed to optimize densification in 8YSZ cylindrical and dog-bone samples, employing a central composite design combined with response surface methodology. Results predicted optimal electric field and current density values for densification across both geometries, elucidating their effects on onset and sample temperatures. Validation showed less than 5 % variation from experimental values, except for onset temperature and T BBR in dog-bone samples, with 11 % and 13 % variations, respectively. These findings suggest the technique could be extended to incorporate additional process boundary conditions for different sample geometries, broadening its applicability. (AU)

• FAPESP's process: 18/19370-6 - Electric-Field Assisted Processing of Electroceramics: (micro)structural characteristics and dielectric properties
• Grantee: Lilian Menezes de Jesus
• Support Opportunities: Scholarships abroad - Research
• FAPESP's process: 19/14677-9 - Influence of the Multi Step Flash Sintering technique on the microstructural control of ZrO2
• Grantee: Eliria Maria de Jesus Agnolon Pallone
• Support Opportunities: Regular Research Grants
• FAPESP's process: 15/07319-8 - Study ultra rapid sintering and low energy consumption: flash Sintering
• Grantee: Eliria Maria de Jesus Agnolon Pallone
• Support Opportunities: Regular Research Grants
• FAPESP's process: 21/06509-9 - Ionic conductor glass-ceramics sintering with concurrent crystallisation using flash sintering
• Grantee: João Vitor Campos
• Support Opportunities: Scholarships in Brazil - Post-Doctoral
• FAPESP's process: 23/18168-7 - Ultrafast crystallization of high-entropy NaSICON superionic conductor for all-solid-state batteries
• Grantee: João Vitor Campos
• Support Opportunities: Scholarships abroad - Research Internship - Post-doctor