Slip casting and stress-controlled co-sintering of a complex ceramic Al₂O₃–ZrO₂/Al₂O₃ bi-material component through bevelled interface design for electromagnetic applications
Abstract
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).
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BibTeX
@article{arbelaez2026slip,
title = {{Slip casting and stress-controlled co-sintering of a complex ceramic Al₂O₃–ZrO₂/Al₂O₃ bi-material component through bevelled interface design for electromagnetic applications}},
author = {Lizeth Arbelaez and Cécile Pagnoux and Anne-Lise Adenot-Engelvin and Nicolas Malléjac and Philippe Michaud and Vincent Pateloup and Pierre-Marie Geffroy and Julie Bourret},
journal = {Open Ceramics},
year = {2026},
month = oct,
doi = {10.1016/j.oceram.2026.101011},
url = {https://unilim.hal.science/hal-05797844v1},
note = {CC BY-NC-ND},
}
RIS
TY - JOUR
TI - Slip casting and stress-controlled co-sintering of a complex ceramic Al₂O₃–ZrO₂/Al₂O₃ bi-material component through bevelled interface design for electromagnetic applications
AU - Lizeth Arbelaez
AU - Cécile Pagnoux
AU - Anne-Lise Adenot-Engelvin
AU - Nicolas Malléjac
AU - Philippe Michaud
AU - Vincent Pateloup
AU - Pierre-Marie Geffroy
AU - Julie Bourret
PY - 2026
DA - 2026/10/13
JO - Open Ceramics
DO - 10.1016/j.oceram.2026.101011
UR - https://unilim.hal.science/hal-05797844v1
AB - 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).
SN - 2666-5395
ER -