A general thermodynamically consistent phase-field-micromechanics model of sintering with coupled diffusion and grain motion

Abstract: Sintering is a pivotal technology for processing ceramic and metallic powders into solid objects. A profound understanding of microstructure evolution during sintering is essential for manufacturing products with tailored properties. While various phase-field models have been proposed to simulate microstructure evolution in solid-state sintering, correctly incorporating the crucial densification mechanism, particularly grain motion, remains a challenge. The fundamental obstacle lies in the ad hoc treatment of the micromechanics of grain motion, where the thermodynamical driving force cannot be derived from the system's free energy. This work presents a novel phase-field-micromechanics model for sintering (PFMMS) that addresses this challenge. We define a unified energy law, under which the governing equations for microstructure evolution in sintering are derived using variational principles. Our approach ensures thermodynamic consistency, with the driving force for grain motion derived from the system's free energy. Consequently, the proposed PFMMS guarantees the evolution of microstructure in a direction that reduces the system's energy and eliminates non-densifying phenomena. We rigorously validate PFMMS against recent benchmarks of theoretical and numerical analysis. It is found that PFMMS captures intrinsic stress distribution along and beyond grain boundaries, exhibits system-size-independent shrinkage strain, and maintains thermodynamic equilibrium states. These features are fundamental requirements for a physically consistent sintering model.