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Slip casting and stress-controlled co-sintering of a complex ceramic Al₂O₃–ZrO₂/Al₂O₃ bi-material component through bevelled interface design for electromagnetic applications
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DOI：10.1016/j.oceram.2026.101011.png)
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Abstract
En 中文
In the field of electromagnetic applications, performance depends strongly on radiation pattern design, controlled by the index contrast of multi-material structures. This study investigates the slip-cast fabrication of a complex-geometry high-index ceramic bi-material component combining alumina and zirconia-alumina. A curved disk (100 mm diameter, 3 mm thickness) was successfully produced with a relative density above 99% and dimensional control within 0.5 mm. Optimized suspensions enabled compatible sintering behavior, with matched shrinkage and thermal expansion coefficients. Finite element simulations showed that a beveled interface reduced residual stresses compared with a sharp interface, although the thermoelastic model likely overestimated stress values due to neglecting high-temperature stress relaxation phenomena. Electromagnetic characterization confirmed permittivities of 9.5 and 17.4, and the final component exhibited defect-free interfaces and improved radiation patterns at 2.5 and 5 GHz. These results demonstrate the feasibility of multi-material ceramic radomes for advanced electromagnetic applications close to room temperature (-20°C-+80°C).
Keywords:
Slip casting
sintering kinetics
zirconia-alumina co-sintering
electromagnetic scattering
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