Finite element modeling of distortion during liquid phase sintering

Liquid phase sintering (LPS) is a common technique to consolidate materials that are difficult to process by fusion techniques, such as tungsten heavy alloys. One of the major processing difficulties associated with liquid phase sintered alloys is component distortion and loss of component shape. In LPS, this distortion is the result of viscous flow driven by curvature effects and gravity. A finite element model is developed for viscous flow of the semisolid sintering structure using Stokes equations. This model considers solid volume fraction and effective viscosity of the solid-liquid mixture. The simulation predictions are compared to distortion results for microgravity and ground-based sintering experiments, and they show good agreement. The model results indicate that the effective semisolid viscosity is significantly greater than the liquid metal viscosity. Hence, future work needs to quantitatively examine the factors controlling viscosity and the benefits from such high viscosities in liquid phase sintered systems.