Strategy of Sintering Ceramics Under Extreme Conditions

Shuai Fu , Weimin Wang , Hanxing Liu , Wei Ji

Interdisciplinary Materials ›› 2026, Vol. 5 ›› Issue (2) : 243 -251.

PDF (3019KB)
Interdisciplinary Materials ›› 2026, Vol. 5 ›› Issue (2) :243 -251. DOI: 10.1002/idm2.70042
PERSPECTIVE
Strategy of Sintering Ceramics Under Extreme Conditions
Author information +
History +
PDF (3019KB)

Abstract

Advanced ceramics play a critical role in high-tech industries. Development of advanced ceramics faces two major challenges: contradiction between densification and grain growth during sintering leading to “mechanical strength ceiling”, contradiction between hardness and fracture toughness. We have proposed and developed the strategy of extreme condition sintering, which has provided valuable insights into addressing the challenges. This study summarizes the recent advancements of the new techniques in the sintering of ceramics under extreme conditions, including ultra-fast heating, strong electric fields, high or ultra-high pressure, and multi-field coupling, and puts forward the proposal and perspective for future work.

Keywords

advanced ceramics / electric field / extreme condition / high-pressure / multi-field coupling / sintering technology / ultra-fast

Cite this article

Download citation ▾
Shuai Fu, Weimin Wang, Hanxing Liu, Wei Ji. Strategy of Sintering Ceramics Under Extreme Conditions. Interdisciplinary Materials, 2026, 5 (2) : 243-251 DOI:10.1002/idm2.70042

登录浏览全文

4963

注册一个新账户 忘记密码

References

[1]

W. D. Kingery, H. K. Bowen, and D. R. Uhlmann, Introduction to Ceramics (John Wiley & Sons, 1976).

[2]

S. J. L. Kang, Sintering: Densification, Grain Growth & Microstructure (Butterworth-Heinemann, 2005).

[3]

Z. Zhong, B. Zhang, Y. Jin, et al., “Design and Anti-Penetration Performance of TiB/Ti System Functionally Graded Material Armor Fabricated by SPS Combined With Tape Casting,” Ceramics International 46, no. 18, Part A (2020): 28244–28249.

[4]

I. W. Chen and X. H. Wang, “Sintering Dense Nanocrystalline Ceramics Without Final-Stage Grain Growth,” Nature 404 (2000): 168–171.

[5]

M. G. Lee, S. Y. Chung, and S. J. L. Kang, “Boundary Faceting-Dependent Densification in a BaTiO3 Model System,” Acta Materialia 59 (2011): 692–698.

[6]

Z. A. Munir, D. V. Quach, and M. Ohyanagi, “Electric Current Activation of Sintering: A Review of the Pulsed Electric Current Sintering Process,” Journal of the American Ceramic Society 94, no. 1 (2011): 1–19.

[7]

Y. C. Wang and Z. Y. Fu, “Study of Temperature Field in Spark Plasma Sintering,” Materials Science and Engineering B 90, no. 1 (2002): 34–37.

[8]

G. Bernard-Granger, N. Monchalin, and C. Guizard, “Sintering of Ceramic Powders: Determination of the Densification and Grain Growth Mechanisms From the ‘Grain Size/Relative Density’ Trajectory,” Scripta Materialia 57 (2007): 137–140.

[9]

F. Meng, Z. Fu, J. Zhang, et al., “Rapid Densification of Nano-Grained Alumina by High Temperature and Pressure With a Very High Heating Rate,” Journal of the American Ceramic Society 90, no. 4 (2007): 1262–1264.

[10]

J. Liu, Z. Fu, W. Wang, et al., “Grain Growth Stagnation in the Dense Nanocrystalline Yttria Prepared by Combustion Reaction and Quick Pressing With an Ultra-High Heating Rate,” Journal of the European Ceramic Society 34, no. 10 (2014): 2475–2482.

[11]

J. Liu, Z. Fu, W. Wang, et al., “Ultra-High Heating Rate Densification of Nanocrystalline Magnesia at High Pressure and Investigation on Densification Mechanisms,” Journal of the European Ceramic Society 34 (2014): 3095–3102.

[12]

K. Wang, T. Tan, Z. Fu, et al., “Study on Atom Diffusion Under the Treatment by Pulse Current Heating,” Materials Science and Engineering: B 135, no. 2 (2006): 154–161.

[13]

W. Kun, F. Zhengyi, W. Weimin, W. Yucheng, Z. Jinyong, and Z. Qingjie, “Study on Fabrication and Mechanism in of Porous Metals by Spark Plasma Sintering,” Journal of Materials Science 42, no. 1 (2007): 302–306.

[14]

D. M. Zhang, Z. Y. Fu, J. K. Guo, et al., “Twin Effects on TiB2 Ceramic During Pulse Electric Current Sintering,” Materials Science and Technology 20, no. 1 (2024): 1100–1102.

[15]

W. Ji, B. Parker, S. Falco, J. Y. Zhang, Z. Y. Fu, and R. I. Todd, “Ultra-Fast Firing: Effect of Heating Rate on Sintering of 3YSZ, With and Without an Electric Field,” Journal of the European Ceramic Society 37, no. 7 (2017): 2547–2551.

[16]

W. Ji, J. Zhang, W. Wang, Z. Fu, and R. I. Todd, “The Microstructural Origin of Rapid Densification in 3YSZ During Ultra-Fast Firing With or Without an Electric Field,” Journal of the European Ceramic Society 40, no. 15 (2020): 5829–5836.

[17]

G. M. Jones, M. Biesuz, W. Ji, et al., “Promoting Microstructural Homogeneity During Flash Sintering of Ceramics Through Thermal Management,” MRS Bulletin 46, no. 1 (2021): 59–66.

[18]

W. Ji, S. S. Rehman, W. Wang, et al., “Sintering Boron Carbide Ceramics Without Grain Growth by Plastic Deformation as the Dominant Densification Mechanism,” Scientific Reports 5 (2015): 15827.

[19]

H. Xu, W. Ji, J. Jiang, et al., “Contribution of Boundary Non-Stoichiometry to the Lower-Temperature Plasticity in High-Pressure Sintered Boron Carbide,” Nature Communications 14, no. 1 (2023): 4889.

[20]

H. Xu, J. Zou, W. Wang, H. Wang, W. Ji, and Z. Fu, “Densification Mechanism and Microstructure Characteristics of Nano- and Micro-Crystalline Alumina by High-Pressure and Low Temperature Sintering,” Journal of the European Ceramic Society 41 (2021): 635–645.

[21]

Y. Li, J. Zou, Q. Zhu, et al., “Microstructure Characterization of High-Pressure Induced Texture in Fully Densified Zirconium Diboride Ceramics,” Journal of the American Ceramic Society 106 (2023): 39–45.

[22]

Y. Zheng, J. Zou, W. Liu, W. Wang, W. Ji, and Z. Fu, “High Pressure Sintering of Fully Dense Tantalum Carbide Ceramics With Limited Grain Growth,” Journal of the European Ceramic Society 43, no. 12 (2023): 5117–5124.

[23]

B. Ke, W. Ji, J. Zou, W. Wang, and Z. Fu, “Densification Mechanism, Microstructure and Mechanical Properties of ZrC Ceramics Prepared by High-Pressure Spark Plasma Sintering,” Journal of the European Ceramic Society 43, no. 8 (2023): 3053–3061.

[24]

Q. Zhu, W. Ji, J. Zou, et al., “Strengthening Hf0.95Ta0.05B2 Ceramic With Ultrafine Grains and High-Density Dislocations,” Journal of the European Ceramic Society 43, no. 13 (2023): 6599–6605.

[25]

Q. Zhu, J. Zou, W. Wang, et al., “Low Temperature Sintering of Hf0.95Nb0.05B2-Based Ceramics With Submicron-Scaled Grains and Enhanced Mechanical Properties,” Journal of the European Ceramic Society 43, no. 15 (2023): 7215–7220.

[26]

B. Ke, J. Zou, W. Wang, W. Ji, and Z. Fu, “Fabrication and Improved Properties of ZrC-SiC-ZrB2 Ceramics by Ultra-High Pressure Sintering,” Journal of the European Ceramic Society 44, no. 12 (2024): 7405–7410.

[27]

M. Zhao, Q. Zhu, J. Zou, et al., “Binderless Nanocrystalline Tungsten Carbide With Enhanced Hardness Induced by High-Pressure Sintering,” Journal of the European Ceramic Society 44, no. 8 (2024): 4875–4886.

[28]

X. Qin, J. Zou, W. Wang, W. Ji, and Z. Fu, “High-Pressure Regulated Phase Transition Enables In Situ Synthesis of High-Performance Dual-Phase Si3N4 Ceramics,” Science China Materials 68, no. 11 (2025): 4285–4291.

[29]

A. Cheng, J. Zou, W. Wang, W. Ji, and Z. Fu, “Nanocrystalline Yttria-Stabilized Hafnia Ceramics With Low Thermal Conductivity and Enhanced Mechanical Properties,” Journal of the American Ceramic Society 108 (2025): e20556.

[30]

S. Fu, W. Ji, and H. Liu, “Enhanced Properties of Fine-Grain Titanium Diboride With High Dislocation Density Fabricated by High-Pressure Sintering,” Journal of the American Ceramic Society 108 (2025): e20404.

[31]

T. Hu, M. Lin, J. Zou, W. Wang, W. Ji, and Z. Fu, “Pressure-Controlled Synergy Between Dehydrogenation and Densification in TiH2 Sintering,” Journal of the European Ceramic Society 45, no. 14 (2025): 117551.

[32]

H. Xu, W. Ji, W. Guo, et al., “Enhanced Mechanical Properties and Oxidation Resistance of Zirconium Diboride Ceramics via Grain-Refining and Dislocation Regulation,” Advanced Science 9 (2022): 2104532.

[33]

H. Xu, J. Zou, R. Crookes, et al., “Enhanced Properties of Nanocrystalline Alumina Ceramic With Compressive Prestress and Coherently Aligned Nanograins,” Journal of the American Ceramic Society 107 (2024): 1949–1958.

[34]

Z. Wu, W. Ji, J. Zhang, et al., “Grain-Refining Fabrication of Nanocrystalline (La0.2Nd0.2Sm0.2Gd0.2Eu0.2)2Zr2O7 High-Entropy Ceramics by Ultra-High Pressure Sintering,” Journal of Materials Science & Technology 167 (2023): 205–212.

[35]

J. Gu and Z. Fu, “Pressure-Enhanced Densification of TaC Ceramics During Flash Spark Plasma Sintering,” Journal of the American Ceramic Society 102, no. 1 (2019): 98–103.

[36]

B. Niu, F. Zhang, J. Zhang, W. Ji, W. Wang, and Z. Fu, “Ultra-Fast Densification of Boron Carbide by Flash Spark Plasma Sintering,” Scripta Materialia 116 (2016): 127–130.

[37]

J. Xie, H. Ping, T. Tan, et al., “Bioprocess-Inspired Fabrication of Materials With New Structures and Functions,” Progress in Materials Science 105 (2019): 100571.

[38]

H. Ping, W. Wagermaier, N. Horbelt, et al., “Mineralization Generates Megapascal Contractile Stresses in Collagen Fibrils,” Science 376 (2022): 188–192.

[39]

W. Fang, H. Ping, X. Li, et al., “Oriented Strontium Carbonate Nanocrystals Within Collagen Films for Flexible Piezoelectric Sensors,” Advanced Functional Materials 31 (2021): 2105806.

[40]

J. Wei, H. Ping, J. Xie, et al., “Bioprocess-Inspired Microscale Additive Manufacturing of Multilayered TiO2/Polymer Composites With Enamel-Like Structures and High Mechanical Properties,” Advanced Functional Materials 30, no. 4 (2020): 1904880.

[41]

Y. Li, Y. Kong, B. Xue, et al., “Mechanically Reinforced Artificial Enamel by Mg2+-Induced Amorphous Intergranular Phases,” ACS Nano 16 (2022): 10422–10430.

[42]

Z. Zou, H. Ping, Q. Cheng, H. Gao, Y. Zhu, and Z. Fu, “Idea of Biomineralization-Inspired Fabrication for Ceramics at Room or Low Temperature,” National Science Review 12, no. 11 (2025): nwaf428.

[43]

C. Wang, W. Ping, Q. Bai, et al., “A General Method to Synthesize and Sinter Bulk Ceramics in Seconds,” Science 368, no. 6490 (2020): 521–526.

[44]

Z. Guo and R. I. Todd, “Acceleration of Grain Boundary Diffusion During Ultra-Fast Firing (UHS) of Alumina Powder Compacts,” Acta Materialia 282 (2025): 120471.

[45]

U. Anselmi-Tamburini, J. E. Garay, Z. A. Munir, A. Tacca, F. Maglia, and G. Spinolo, “Spark Plasma Sintering and Characterization of Bulk Nanostructured Fully Stabilized Zirconia: Part I. Densification Studies,” Journal of Materials Research 19, no. 11 (2004): 3255–3262.

[46]

U. Anselmi-Tamburini, J. E. Garay, Z. A. Munir, et al., “Spark Plasma Sintering and Characterization of Bulk Nanostructured Fully Stabilized Zirconia: Part II. Characterization Studies,” Journal of Materials Research 19, no. 11 (2004): 3263–3269.

[47]

M. Cologna, B. Rashkova, and R. Raj, “Flash Sintering of Nanograin Zirconia in ≪ 5 S at 850 Degrees C,” Journal of the American Ceramic Society 93, no. 11 (2010): 3556–3559.

[48]

Z. A. Munir, U. Anselmi-Tamburini, and M. Ohyanagi, “The Effect of Electric Field and Pressure on the Synthesis and Consolidation of Materials: A Review of the Spark Plasma Sintering Method,” Journal of Materials Science 41 (2006): 763–777.

[49]

Y. Tian, B. Xu, D. Yu, et al., “Ultrahard Nanotwinned Cubic Boron Nitride,” Nature 493, no. 7432 (2013): 385–388.

[50]

Q. Huang, D. Yu, B. Xu, et al., “Nanotwinned Diamond With Unprecedented Hardness and Stability,” Nature 510, no. 7504 (2014): 250–253.

[51]

Z. Xie, S. Li, and L. An, “A Novel Oscillatory Pressure-Assisted Hot Pressing for Preparation of High-Performance Ceramics,” Journal of the American Ceramic Society 97 (2014): 1012–1015.

[52]

N. Sun, T. Zhu, Y. Su, et al., “Excellent Tribological Properties and Unique Wear-Resistance Mechanism of Binderless Tungsten Carbide Prepared via Two-Step Oscillatory Pressure Sintering,” Journal of the European Ceramic Society 44 (2024): 116665.

[53]

J. Guo, H. Guo, A. L. Baker, et al., “Cold Sintering: A Paradigm Shift for Processing and Integration of Ceramics,” Angewandte Chemie International Edition 55 (2016): 11457–11461.

[54]

J. Gao, Z. Xia, Q. Ding, et al., “Cold Sintering of Highly Transparent Calcium Fluoride Nanoceramic as a Universal Platform for High-Power Lighting,” Advanced Functional Materials 33 (2023): 2302088.

[55]

Z. Wang, J. Gao, J. Song, et al., “Ultrasonic-Assisted Hot Pressing (UAHP): A Novel Strategy to Enhance Densification and Improve the Mechanical Properties of B4C,” Journal of Advanced Ceramics 15, no. 2 (2026): 9221236.

RIGHTS & PERMISSIONS

2026 The Author(s). Interdisciplinary Materials published by Wuhan University of Technology and John Wiley & Sons Australia, Ltd.

PDF (3019KB)

1

Accesses

0

Citation

Detail

Sections
Recommended

/