Programmable and rapid fabrication of complex-shape ceramics

Yao Shan, Xuemu Li, Wanjun Zhao, Xiaodan Yang, Yuanyi Wang, Zhuomin Zhang, Shiyuan Liu, Xiaote Xu and Zhengbao Yang ()
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Yao Shan: Hong Kong University of Science and Technology
Xuemu Li: Hong Kong University of Science and Technology
Wanjun Zhao: Beijing Institute of Technology
Xiaodan Yang: Hong Kong University of Science and Technology
Yuanyi Wang: Hong Kong University of Science and Technology
Zhuomin Zhang: Hong Kong University of Science and Technology
Shiyuan Liu: Hong Kong University of Science and Technology
Xiaote Xu: Hong Kong University of Science and Technology
Zhengbao Yang: Hong Kong University of Science and Technology

Nature Communications, 2024, vol. 15, issue 1, 1-9

Abstract: Abstract Shaping of ceramics is crucial. Current techniques cannot easily and rapidly shape ceramics without weakening their properties, especially for piezoceramics. We present an ultrafast ceramic shaping method that leverages thermomechanical fields to deform and sinter ceramic powder compacts into complex-shaped ceramics. The shape-forming process hinges on: (1) the implementation of a precise thermal field to activate optimal deformability, and (2) the application of sufficient mechanical loads to guide deformation. We employ a programmable carbon-felt Joule heater that concurrently function as mechanical carriers, effectively transferring applied loads to the ceramic powder compacts. Using this ultrafast shaping and sintering (USS) method, we fabricate barium titanate (BT) piezoceramics in twisted shape, arch shape and with micropatterns. The USS method is energy-friendly (requiring approximately 1.06 kJ mm−3) and time-efficient (in several minutes level). Overall, the USS method offers an effective solution for shaping ceramics and extends them to 3D geometries with enhanced versatility.

Date: 2024
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DOI: 10.1038/s41467-024-54393-w

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