University of California

National Technology & Engineering Solutions of Sandia, LLC

Baolong Zheng

Enrique J Lavernia

Todd Monson

Yizhang Zhou

A method of forming a consolidated component having a complex shape includes providing a first component having a first shape similar to the complex shape. The method further includes placing the first component in a chamber and surrounding the first component with a medium. The method further includes applying pressure and at least one of heat or electricity into the chamber to process the first component to form a consolidated component having the complex shape.

Isostatic pressure spark plasma sintering (IP-SPS) net shaping of components using nanostructured materials

Bulk iron nitride can be synthesized from iron nitride powder by spark plasma sintering. The iron nitride can be spark plasma sintered at a temperature of less than 600&#xb0; C. and a pressure of less than 600 MPa, with 400 MPa or less most often being sufficient. High pressure SPS can consolidate dense iron nitrides at a lower temperature to avoid decomposition. The higher pressure and lower temperature of spark discharge sintering avoids decomposition and limits grain growth, enabling enhanced magnetic properties. The method can further comprise synthesis of nanocrystalline iron nitride powders using two-step reactive milling prior to high-pressure spark discharge sintering.

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Baolong Zheng