Finite-difference model for the reaction sintering of oxide ceramics by direct oxidation of intermetallic powder compacts

A kinetic model for the reaction sintering of oxide ceramics in the system Al₂O₃–SiO₂–ZrO₂ using mixtures of intermetallic compounds is presented. A 2D finite-difference model is developed to describe the exothermic gas-solid reactions taking place during the firing of ZrAl₃/ZrSi₂ powder compacts. The model accounts for the oxidation kinetics of the powder particles, as well as the consumption and diffusion of gaseous oxygen through the porous matrix. Additionally, possible changes in the pore structure of the green body due to the oxidation reactions and sintering effects are incorporated in the model. The resulting differential equations are coupled with a two-dimensional Fourier heat balance equation leading to a system of nonlinear partial differential equations, which is solved by the numerical method of lines. The influence of different processing parameters like sample composition and heating cycle on the reaction sintering process is investigated and the model-predicted reaction behaviour is compared to experimental results.