Programmable and rapid fabrication of complex-shape ceramics

Yao Shan; Xuemu Li; Wanjun Zhao; Xiaodan Yang; Yuanyi Wang; Zhuomin Zhang; Shiyuan Liu; Xiaote Xu; Zhengbao Yang

doi:10.1038/s41467-024-54393-w

Programmable and rapid fabrication of complex-shape ceramics

Nat Commun. 2024 Nov 18;15(1):9973. doi: 10.1038/s41467-024-54393-w.

Authors

Yao Shan^#^{1

2}, Xuemu Li^#¹, Wanjun Zhao^#³, Xiaodan Yang^{1

4}, Yuanyi Wang¹, Zhuomin Zhang^{1

4}, Shiyuan Liu¹, Xiaote Xu¹, Zhengbao Yang⁵

Affiliations

¹ Department of Mechanical and Aerospace Engineering, Hong Kong University of Science and Technology, Hong Kong, China.
² Department of Chemistry, Purdue University, Indiana, USA.
³ State Key Laboratory of Explosion Science and Technology, Beijing Institute of Technology, Beijing, China.
⁴ Department of Mechanical Engineering, City University of Hong Kong, Hong Kong, China.
⁵ Department of Mechanical and Aerospace Engineering, Hong Kong University of Science and Technology, Hong Kong, China. [email protected].

^# Contributed equally.

PMID: 39557886
DOI: 10.1038/s41467-024-54393-w

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.