Spark plasma sintering of α/β-SiAlON ceramic end mill rods: Electro-thermal simulation, microstructure, mechanical properties, and machining performance

Spark plasma sintering (SPS) is a highly efficient method for the preparation of α/β-SiAlON ceramics. However, rapid large-scale ceramic components with reliable mechanical properties difficult via SPS due to their near-insulating properties. In this study, high-performance end mill rods large aspect ratios were successfully prepared SPS. Two different types processes (namely vertical-round-rod (VRR) and horizontal-square-rod (HSR) processes) developed, effects on phase composition, microstructure, properties, machining performance studied. The electric temperature field distributions during studied through an electro-thermal simulation. simulated experimental are in good agreement. contrast VRR samples, HSR samples small axial size show uniform distribution satisfactory microstructures within certain range dimensions, expected composition; furthermore, elongated β-SiAlON grains preferentially oriented direction perpendicular pressure direction. As result, exhibit better than samples.