Spark plasma sintering: A solid-state sustainable recycling technique

This review comprehensively explores the emerging role of Spark Plasma Sintering (SPS) as a sustainable and versatile solid-state recycling technique across various industries. Emphasizing its advantages over conventional methods, SPS efficiently consolidates metallic, ceramic, and composite waste materials at lower temperatures and shorter times, thereby reducing energy consumption and environmental impact. The review highlights recent progress in the application of SPS for recycling aluminum, magnesium, copper alloys, and ceramics, as well as its utility in fabricating high-performance materials for biomedical, energy, and magnetic applications. Microstructural control, densification mechanisms, and property enhancements achieved through SPS are analyzed, illustrating its capability in producing dense, crack-free, and tailored microstructures. Additionally, the article discusses the significant sustainability implications of SPS, including resource conservation, waste reduction, and a lower carbon footprint, underlining its potential to support a circular economy. Challenges and research gaps, such as process optimization, scale-up, real-time monitoring, and environmental assessment, are identified, proposing future directions toward industrial adoption and ecological sustainability.