Tailoring the Microstructure and Porosity of Porous Piezoelectric Ceramics for Ultrasonic Transducer Application

Porous piezoelectric ceramics and composites are advantageous for ultrasonic transducers due to their capability to decouple longitudinal and transverse modes, their improved voltage sensitivity, and their enhanced acoustic matching. However, the design and fabrication of porous piezoelectric ultrasonic transducers with excellent electromechanical properties are still challenging. In this work, porous lead zirconate titanate (PZT) ceramics with an aligned pore structure were prepared using the freeze-cast technique, and the effect of porous structure and porosity on the electromechanical parameters was investigated. The introduction of an aligned pore structure is beneficial to enhance the electromechanical properties and reduce the acoustic impedance. A high <i>d</i>₃₃ (∼530 pC/N), a higher <i>k</i>_t (∼0.676), and a lower acoustic impedance (∼10.4 MRalys) were achieved in the porous PZT ceramic with the porosity of 44 vol %. The effect of porosity and pore structure on the decoupling degree of vibration modes and ferroelectric polarization was considered to correct the homogeneous medium model, which can quantify the relationship between the <i>k</i>_t and porosity of the porous structure. A demonstration of a piezoelectric ultrasonic transducer based on freeze-cast porous PZT ceramics was presented, which exhibits a -6 dB bandwidth of 52% and a theoretical axial resolution of 520 μm. This work therefore provides a potential alternative of piezoelectric ultrasonic transducers for nondestructive testing and imaging applications.