A review of microstructure evolution and performance improvements in emerging sintering processes under controlled energy input

Abstract

This review provides a comprehensive examination of microstructure evolution under varied energy input conditions, focusing on how thermal and electrical factors influence densification and structural transformation. It begins with conventional sintering of binder-jetted materials, where low thermal energy input governs the steady-state development of green body microstructures. The review then explores cyclic thermal inputs that induce phase transitions, enhancing densification and structural optimization. Finally, it addresses sintering with high electrical energy input, where electric fields enable ultra-fast densification and non-equilibrium microstructural control. By establishing an energy-centric framework, this work introduces a novel perspective on both conventional and emerging sintering technologies, including additive manufacturing and electric field-assisted methods. It offers a conceptual shift toward energy-directed processing, guiding future strategies in sintering science and microstructure engineering.