During the microwave sintering of a polymer-ceramic composite plasma discharge is experienced. The discharge could occur failure of the power source. The solution proposed by the paper is original, no similar solutions being presented by the literature. It consists of using a polymer-ceramic composite protective panel, to stop the plasma discharge to the entrance of the guiding tunnel. Six composites resulted by combining three polymers, Polytetrafluoroethylene (PTFE), STRATITEX composite and Polyvinylchloride (PVC) with two natural ceramics containing calcium carbonate: Rapana Thomasiana (RT) sea-shells and beach sand were used to build the protective panel.Theoretical balance of the power to the panel was analysed and the thermal field was determined. It was applied heating using 0.6-1.2-1.8-2.4-3.0 kW microwave beam power. The panels were subjected to heating with and without material to be sintered. It was analyzed: RT chemical (CaCO3 as Calcite and Aragonite), burned area (range: 200-4000 mm2) and penetration (range: 1.6-5.5 mm), and thermal analysis of the burned areas comparing to the original data. PTFE-RT composite proved the lowest penetration to 0.6 and 1.2 kW. Other 1.2 kW all composites experienced vital failures. Transformation of the polymer matrix of composite consisted of slightly decreasing of the phase shifting temperature and of slightly increasing of the melting start and liquidus temperature.
Keywords: Finite element analysis; microwave heating; numerical simulation of heat flow; plasma discharge; polymer-shell powder composite; thermal degradation; thermal field.