During the spark plasma sintering (SPS) consolidation process, the pressure affects the densification and microstructure evolution of the sintered body. In this paper, the W-Cr-Y-Zr alloy powder was heated to 1000 °C under different applied pressure conditions using spark plasma sintering process, and the effect of pressure on the densification process and microstructure was analyzed. Due to the low sintering temperature, the crystalline size of all the produced W-Cr-Y-Zr alloy is less than 10 nm, which is close to that of the original powders. Cr-rich phase can be detected in the sintered samples due to spinodal decomposition. It is found in this work that the external pressure will increase the contact area between the powder particles, resulting in a higher local pressure at the particle contact, which promotes densification by sliding between the particles under the condition of softening of the particle surface. Additionally, according to the viscous flow theory, the viscous flow activation energy decreases with the increase of pressure. This is because the pressure provides additional driving force to the powder viscous flow process and accelerates the powder shrinkage.
