Single Step Processing of an Integrated FGM BaTiO₃-Ni Capacitor for Power Modules’ Assembly

The miniaturization of power electronic devices is pushing manufacturers to improve the multifunctionality of components. Obtaining new materials with heterogeneous electrical properties is a challenge. In this work, the objective is to prepare, in a single step processing, a ceramic capacitor, including a thick metallization. This device will be a first step toward its integration in a power module. The assembly of a metal and ceramics is a challenge due to the difference of properties of these materials. A new BaTiO3-Ni functionally graded material (FGM) has been obtained by spark plasma sintering (SPS) co-sintering. The processing parameters of the BaTiO3-Ni FGM are optimized to target highly dense material with controlled microstructure. In this case, a crack free device is obtained with controlled dielectric properties and can be integrated in a power module device. The processing leading to the fabrication of this FGM in one step can be used for other components in power electronics applications.