Abstract

Currently, there are no studies on the spark plasma sintering (SPS) of Fe-SiC cermets, despite their use in severe wear applications and potential as a low-cost alternative to WC or Ti(C,N). This work systematically investigates the effects of current mode (continuous vs. pulsed), particle size distribution (monomodal vs. bimodal), and sintering time (5 vs. 10 min) on Fe-50 wt% SiC cermets processed by SPS at 1100 degrees C and 50 MPa. The combination of continuous current and bimodal powders for 5 min achieved near-theoretical densification (99.93 %) while simultaneously improving toughness (>11 MPa & centerdot;root m ) and hardness (similar to 7 GPa), minimizing brittle phase formation. In contrast, pulsed current and longer sintering times increased porosity and degraded properties. Microstructural analysis showed stable interfaces with smooth elastic modulus gradients and controlled graphite precipitation. These findings demonstrate that precise SPS parameter control can balance densification and mechanical integrity, providing a clear framework of microstructural properties of the process for designing competitive, robust, and cost-effective Fe-SiC cermets.