This study demonstrates the effect of the compaction pressure on the microstructure and properties of pressureless-sintered W bodies. W powders are synthesized by ultrasonic spray pyrolysis and hydrogen reduction using ammonium metatungstate hydrate as a precursor. Microstructural investigation reveals that a spherical powder in the form of agglomerated nanosized W particles is successfully synthesized. The W powder synthesized by ultrasonic spray pyrolysis exhibits a relative density of approximately 94% regardless of the compaction pressure, whereas the commercial powder exhibits a relative density of 64% under the same sintering conditions. This change in the relative density of the sintered compact can be explained by the difference in the sizes of the raw powder and the densities of the compacted green body. The grain size increases as the compaction pressure increases, and the sintered compact uniaxially pressed to 50 MPa and then isostatically pressed to 300 MPa exhibits a size of 0.71 m. The Vickers hardness of the sintered W exhibits a high value of 4.7 GPa, mainly due to grain refinement.

Aluminum nitride (AlN) has excellent electrical insulation property, high thermal conductivity, and a low thermal expansion coefficient; therefore, it is widely used as a heat sink, heat-conductive filler, and heat dissipation substrate. However, it is well known that the AlN-based materials have disadvantages such as low sinterability and poor mechanical properties. In this study, the effects of addition of various amounts (1-6 wt.%) of sintering additives Y2O3 and Sm2O3 on the thermal and mechanical properties of AlN samples pressureless sintered at 1850oC in an N2 atmosphere for a holding time of 2 h are examined. All AlN samples exhibit relative densities of more than 97%. It showed that the higher thermal conductivity as the Y2O3 content increased than the Sm2O3 additive, whereas all AlN samples exhibited higher mechanical properties as Sm2O3 content increased. The formation of secondary phases by reaction of Y2O3, Sm2O3 with oxygen from AlN lattice influenced the thermal and mechanical properties of AlN samples due to the reaction of the oxygen contents in AlN lattice.

A sintered body of TiB2-reinforced iron matrix composite (Fe-TiB2) is fabricated by pressureless-sintering of a mixture of titanium hydride (TiH2) and iron boride (FeB) powders. The powder mixture is prepared in a planetary ball-mill at 700 rpm for 3 h and then pressurelessly sintered at 1300, 1350 and 1400oC for 0-2 h. The optimal sintering temperature for high densities (above 95% relative density) is between 1350 and 1400oC, where the holding time can be varied from 0.25 to 2 h. A maximum relative density of 96.0% is obtained from the (FeB+TiH2) powder compacts sintered at 1400oC for 2 h. Sintered compacts have two main phases of Fe and TiB2 along with traces of TiB, which seems to be formed through the reaction of TiB2 formed at lower temperatures during the heating stage with the excess Ti that is intentionally added to complete the reaction for TiB2 formation. Nearly fully densified sintered compacts show a homogeneous microstructure composed of fine TiB2 particulates with submicron sizes and an Fe-matrix. A maximum hardness of 71.2 HRC is obtained from the specimen sintered at 1400oC for 0.5 h, which is nearly equivalent to the HRC of conventional WC-Co hardmetals containing 20 wt% Co.

Cu-30 vol% SiC composites with relatively densified microstructure and a sound interface between the Cu and SiC phases were obtained by pressureless sintering of PCS-coated SiC and Cu powders. The coated SiC powders were prepared by thermal curing and pyrolysis of PCS. Thermal curing at 200 oC was performed to fabricate infusible materials prior to pyrolysis. The cured powders were heated treated up to 1600 oC for the pyrolysis process and for the formation of SiC crystals on the surface of the SiC powders. XRD analysis revealed that the main peaks corresponded to the α-SiC phase; peaks for β-SiC were newly appeared. The formation of β-SiC is explained by the transformation of thermally-cured PCS on the surface of the initial α-SiC powders. Using powder mixtures of coated SiC powder, hydrogen-reduced Cu-nitrate, and elemental Cu powders, Cu-SiC composites were fabricated by pressureless sintering at 1000 oC. Microstructural observation for the sintered composites showed that the powder mixture of PCS-coated SiC and Cu exhibited a relatively dense and homogeneous microstructure. Conversely, large pores and separated interfaces between Cu and SiC were observed in the sintered composite using uncoated SiC powders. These results suggest that Cu-SiC composites with sound microstructure can be prepared using a PCS coated SiC powder mixture.

Two sintering methods of a pressureless sintering and a spark-plasma sintering are tested to densify the Fe-TiC composite powders which are fabricated by high-energy ball-milling. A powder mixture of Fe and TiC is prepared in a planetary ball mill at a rotation speed of 500 rpm for 1h. Pressureless sintering is performed at 1100, 1200 and 1300oC for 1-3 hours in a tube furnace under flowing argon gas atmosphere. Spark-plasma sintering is carried out under the following condition: sintering temperature of 1050oC, soaking time of 10 min, sintering pressure of 50 MPa, heating rate of 50oC, and in a vacuum of 0.1 Pa. The curves of shrinkage and its derivative (shrinkage rate) are obtained from the data stored automatically during sintering process. The densification behaviors are investigated from the observation of fracture surface and cross-section of the sintered compacts. The pressureless-sintered powder compacts show incomplete densification with a relative denstiy of 86.1% after sintering at 1300oC for 3h. Spark-plasma sintering at 1050oC for 10 min exhibits nearly complete densification of 98.6% relative density under the sintering pressure of 50 MPa.

The pressureless sintering behavior of /Cu powder mixtures, prepared from /CuO and /Cu-nitrate, has been investigated. Microstructural observation revealed that powders with nano-sized Cu particles could be synthesized by hydrogen reduction method. The specimens, pressureless-sintered at for 4 min using infrared heating furnace with the heating rate of /min, showed the relative density of above 90%. Maximum hardness of 16.1 GPa was obtained in /MgO/Cu nanocomposites. The nanocomposites exhibited the enhanced fracture toughness of 4.3-5.7 , compared with monolithic . The mechanical properties were discussed in terms of microstructural characteristics

Sintering behavior of iron nanopowder agglomerate compact prepared by slurry compaction method was investigated. The Fe nanopowder agglomerates were prepared by hydrogen reduction of spray dried agglomerates of ball-milled nanopowder at various reduction temperatures of , and , respectively. It was found that the Fe nanopowder agglomerates produced at higher reduction temperature have a higher green density compact which consists of more densified nanopowder agglomerates with coarsed nanopowders. The sintering behavior of the Fe nanopowder agglomerates strongly depended on the powder packing density in the compact and microstructure of the agglomerated nanopowder. It was discussed in terms of two sintering factors affecting the entire densification process of the compact.