capability of near net-shape molding for fabricating very fine scale preforms; PZT element dimensions only 30pm wide have been demonstrated. The as-sintered surface of these elements indicates that the PZT ceramic microstructure is dense and uniform,n consisting of equiaxed grains 2-3pm in diameter.
Figure 3: Injection Molded 1-3 Composite Preforms. Figure 4: Scanning Electron Micrographs of As-molded
(Upper) and As-sintered (Lower) Surfaces of PZT Fibers
Figure 5: Fine-scale 2-2 Composite formed by Near Netshape olding (Upper Micrograph). As-sintered Surface
(Lower Micrograph).
In order to demonstrate the lay-up approach for composite fabrication, composites of approximately 10 volume percent PZT-5H" fibers and Spurrs epoxy resin were fabricated by epoxy encapsulating laid-up pairs of injection molded and sintered fiber rows followed by grinding away the PZT ceramic stock used to mold the composite preform. Figure 6 shows composite samples made from freshly-compounded PZT/binder mixture and from reused material. Recycling of the compounded and molded material appears to be entirely feasible and results in greatly enhanced material utilization. Table 1 compares the piezoelectric and dielectric properties of injection molded PZT ceramic specimens
with those reported for pressed PZT-5H samples prepared by the powder manufacturer.
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