Fabrication of fine-scale 1-3 Pb(ZrxTi1-x)O3/ ceramic/polymer composites using a modified lost mold method

摘要

Abstract: The processing of piezoelectric Pb(Zr,Ti)O$-3$/ ceramic fiber/polymer composites via a modified lost mold process is discussed. In the lost mold process, plastic molds, which are negatives of the desired ceramic structure, are created. Each mold is filled with a slurry containing fine Pb(Zr,Ti)O$-3$/ powders. After drying, the mold is burned out under controlled atmosphere, and the ceramic is sintered. The sintered ceramic structure is backfilled with polymer, polished, electroded and poled. In the modified lost mold process, several different sacrificial mold were investigated. One type of mold was plastic or wax sheets with precisely punched holes. A second was hollow polyester fibers. The modified mold forming procedure allows rapid prototyping of composites with a variety of connectivities, as well as novel spatial scale and periodicity. Composites with a ceramic fiber as fine as 50 $mu@m in 1-3 connectivity have been demonstrated. A variety of rod shapes, including triangles, hexagons, and diamonds have also been demonstrated. Electromechanical characteristics of a number of composites were determined, and will be reported. The modified lost mold process can be used to form fine-scale, large area piezoelectric ceramic/polymer composites for use in hydrophones, transducers for medical ultrasonic imaging and non-destructive evaluation, and as sensors and actuators in vibration and noise control.!17