Abstract
Materials with gradient microstructures have a wide range of applications such as cutting tools, armor, and electronic devices. However, it is difficult to predict and control the gradient microstructure during processing. In the present work, a continuous porosity gradient was successfully achieved in ZnO material via spark plasma sintering with a large induced thermal gradient. The porosity is overestimated if isothermal prediction is applied. The current work proposed a more accurate prediction of the porosity by considering the stress‐shielding effect caused by the thermal gradient. The shielding effect results from different stress states in the sample due to differential sintering: the hotter side of the specimen experiences a higher strain rate and more shrinkage while the colder side experiences a lower strain rate and less shrinkage simultaneously. Therefore, the axial strains are varied throughout the sample thickness. Using the constituent equations in advanced sintering analysis, the shield stress was calculated to be approximately 13 MPa for the viscoelastic assumption of sintering. To improve the accuracy of predicting porosity gradient, it is necessary to add a load to overcome the shield stress when the materials are sintered with a thermal gradient.
