A combined experimental/numerical methodology is developed to fully consolidate pure ultrafine WC powder by means of Spark Plasma Sintering (SPS) operating under a current-control mode. The investigated applied pressure range from 5 to 80 MPa while the current intensity is held constant to 1400 A.

The developed SPS model employs a moving-mesh technique to account for the electro-thermal contact resistance change during shrinkage and punch sliding. The pressure dependence on the electro-thermal contact resistance is also taken into account by the model.

The experimental and numerical results clearly show the effects of pressure on the microstructure and hardness along the sample radius.

By increasing sintering pressure, complete densification was obtained reducing the peak temperature measured at die surface. By combining experimental and modeling results, a direct correlation among compact microstructure, homogeneity and sintering parameters, such as temperature and applied pressure, can be established.

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