Research on the Influence of the Defects of Materials on Thermal Runaway in Microwave Hybrid Heating for Sintering Processes

Thermal runaway in microwave hybrid heating of ceramics is an unwanted phenomenon which damages the sintered products. The aim of the present study is to establish to what extent the pressing forces of 100, 200 and 300 MPa used in the compaction process and the optimization of the microwave heating mechanism can reduce the occurrence of thermal runaway. Modeling and simulation of temperature distributions alongside defects created by the compaction process are performed in order to evaluate their influence on the stability of MHH. Based on CT scanning, defects with dimensions from 110 to 515 μm are studied in terms of local overheating and how the thermal runaway can lead to internal arc discharge. The results show that samples compacted at 100 MPa and exposed at 600 W injected power reach temperatures peaks around 1010 °C and are affected by major cracks and large melted areas. The samples compacted at 200 and 300 MPa present similar behavior, without arc discharge, but are also affected by cracks. Based on these findings, the MHH process can be applied to sintering processes but with a reduced injected power below 300 W for samples compacted with pressing forces higher than 300 MPa.