Impact of spark plasma sintering technique on high entropy ceramic composites

• High entropy alloy-ceramic composites are advanced innovative material suitable for sustainable applications for the next generation. • Sluggish diffusion of high entropy alloys coupled with chemical stability of ceramics enables the composite to possess high oxidation resistance. • The strength of high entropy alloys and thermal stability of ceramics make the composite good for high temperature applications. • The high heating rate and short sintering time of spark plasma sintering make the technique best for developing composites with refined microstructure and superior properties. This study aims to evaluate the improvement of HEA-ceramic composites processed using SPS, a sintering technology that rapidly densifies and preserves nanostructures. Principally, the review research dwells on assessing the impact of SPS on the properties of HEA-ceramic composites, with special consideration on their microstructural design, interfacial bonding, and toughening mechanisms. The strength of these composites is their excellent performance in challenging environments. It was observed that SPS strengthens composites’ density, hardness, fracture toughness, and resistance to oxidation by inhibiting grain growth and optimizing reinforcement dispersion. Results disclosed that various ceramic reinforcements such as ZrB₂, SiC and TiC provide finer grain boundaries and better crack deflection and bridging, with high resistance to oxidation at high temperatures. Although there are some problems militating against high entropy ceramic composites developed by SPS, such as weak interfacial bonding and poor scalability, SPS shows much promise for making future smart materials. Further improvements can be made to SPS by understanding and optimizing processing parameters and using computational modeling and machine learning for prediction of microstructure and phases present. The study further recommends the use of hybrid reinforcement and environmentally friendly feedstocks to extend the range of applications and scalability of HEA-ceramic composite development technology.