DC electric field‐assisted hot pressing of zirconia: Methodology, phenomenology, and sintering mechanism

Abstract Flash sintering (FS) is an important technique in the field of ceramic sintering. Nevertheless, conventional FS is less attractive for practical applications because of the complex shapes and small sizes of the specimens. In this study, using the novel electric field‐assisted hot pressing (FAHP) technique, we successfully achieved FS during the net‐shape hot pressing (HP) process for the first time. It was found that the 3 mol% yttria‐stabilized zirconia (3YSZ) can be flash sintered at 909°C using a fairly low DC field of 33 V/cm under 30 MPa pressure. The grain sizes of the FAHP‐sintered samples were 20% smaller than that of the HP‐sintered sample. When the current density limit is ≥240 mA/mm 2 , 3YSZ can be fully densified during the flash events. Careful analysis of the sintering curves suggests that although the carrier type or concentration is changed during flash events, it cannot explain the ultrafast densification. Additionally, we devised a qualitative method to analyze the densification mechanism. The results indicated that the ultrafast densification observed during flash events resulted from the synergistic effects of the rapid heating rate and peak sample temperature. Finally, the atomic force microscopy confirmed the lower grain boundary energy for the FAHP‐sintered samples, which accounts for the smaller grain sizes than the HP‐sintered sample. We believe that the FAHP technique could create new possibilities for theoretical and applied research on field‐assisted sintering techniques.