Rapid microwave sintering of functional electroceramic materials

Rapid microwave sintering processes with heating rates of up to 300 °C/min and zero isothermal hold have been implemented using a 5 kW 24 GHz gyrotron system for high-temperature microwave processing of materials. ZnO-based varistor ceramics, BaTiO3/SrTiO3 dielectric ceramics and Gd:CeO2 ceramics for solid electrolyte applications have been sintered to densities of up to 96% of the theoretical value. Using in situ optical dilatometry, correlation between the development of thermal instability under intense volumetric microwave heating and the early onset of densification has been revealed. The influence of the absorbed microwave power on densification and grain growth has been studied by comparing direct and susceptor-assisted microwave heating processes. The possibility of tailoring the microstructure and functional properties of the obtained materials by choosing optimal regimes of rapid microwave sintering is discussed.