A hybrid processing technology for fabricating lead zirconate-based ceramics with high energy storage density, high efficiency, and low sintering temperature

For multilayer ceramic capacitors, co-sintering of ceramics with inner electrodes is a crucial issue. This requires ceramic materials to have a low sintering temperature. In response to this criterion, a hybrid processing technology is proposed in this study. This technology involves mixing of calcined ceramic powders with sol solutions to obtain composite powders. Eventually, sintering temperature of the obtained composite material is reduced from 1300 °C to 1120 °C. This is originated from the introduction of more specific surface areas and more oxygen vacancies by sol solutions, leading to an enhancement of chemical reaction activity. The ceramic powders and the sol solutions used in this work are (Pb 0.94 La 0.04 )(Zr 0.51 Sn 0.47 Hf 0.01 Ti 0.01 )O 3 and (Pb 0.97 La 0.02 )(Zr 0.6 Sn 0.4 )O 3 , respectively. Such composition design helps improve the dielectric constant and polarization intensity. While in the meantime, because of the strong interfacial resistance caused by sol solutions, interfacial insulation as well as electrical breakdown strength can be significantly improved. Consequently, a high energy storage density up to 12.4 J/cm 3 and an efficiency of 92.4% is obtained in this work. Overall, this technology is applicable to a wide range of ceramic material systems, and provides an innovative design and manufacture of ceramics. • A hybrid process technology (HPT) is proposed in which sintering temperature can be reduced by 180 °C for PZ-based material. • A high W rec of 12.4 J/cm 3 and high η of 92.4% in PZ-based material are obtained using the hybrid processing technology. • High BDS and improved polarization are achieved by HPT without sacrificing ε r at low sintering temperature. • Hybrid processing technology is versatile and can be applied to various materials system.