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Agrawal 1998
Agrawal 1998
Microwave processing of ceramics is fast emerging as a new energy transfer, cvhich occurs in conventional technicl(lcs.
field of ceramic processing and material synthesis. The past hlicrowave heating is a function of rhe material being
year has witnessed significant progress in the aspect of processed, and rherc is almost 1009T con~xxsion of elec-
commercialization and application of the technology to new tromagnetic energy into heat, largely within rhe sample
areas. The most significant developments have been the use of itself, unlike with conventional heating where there arc
microwaves in the sintering of non-oxides, such as tungsten significant thermal energy losses. hlicro~\~a~~e heating has
carbide-based components and powdered metals, fabrication many advanrages over con\~entional heating methods
of transparent ceramics, and the design of continuous [l-S]; some of these advantages include, time and cncrg)
microwave systems. sar.ing, very rapid heating rates (>4OO’(:/min), considcr-
ably reduced processing time and rempcruture, fine
Addresses microstructures and hence impro\xd mechanical proper-
Materials Research Laboratory, The Pennsylvania State University, tics, it is en~%amientall~ friendl!; and so on.
University Park, PA 16802, USA; e-mail: dxa4@psu.edu
Current Opinion in Solid State & Materials Science 1998, Other rhan radar, other communicarion purposes and
3:480-485 home-cooking, microwaves are widely used in man!. indcls-
trial applications including. meat tempering, potato chips
Electronic identifier: 1359-0286-003-00480
processing. bacon cooking, drying of pharmrweutical prod-
C Current Chemistry Ltd ISSN 1359-0286 ucts and wlcanization of rubber. In the case of ceramic
processing microwave energy has been in wit since the late
Abbreviations
BMT 1910s wirh a big push in the eighrics: however. this did not
Ba(M9o 3sTao.Gs
BT BaTiO, result in the formation of useful products in the field of
PZT Pb(Zro,~~T~o.~~)O3 ceramics. Ceramic processes \vherc micro\vavcs have Ixen
WC tungsten carbide
applied include: process control. drying of ceramic sanitar>
wares. calcination, decomposition of gaseous species I,!
Introduction niicro\va\x plasma, and sintering of oxide uximics I,)
New developments and innovative ideas in the area of micrownxz plasma. However, excqx for the drying of
materials processing ha\,e often led to the discovery of ceramic uxrcs there is hardlv any orhcr area where
new materials, with interesting and useful properties, microwave technology has been commercially cxploitcd.
and/or new technologies which are faster. better, cheaper Only, recently ha1.e there been reports indicating rhat
and greener. A striking example of such innovations arc sonic sticccss has been achieved in commerci:llizinfi chc
recent de\dopmcnts in the area of microwave processing microwar-c sintering of L\‘(:-based cutting tools [C)].
of ceramics. Although many potential advanrages of uriliz-
ing microwxves to process ceramics have long been rccog- hIany different physical phenomena are in\d\ ed during the
nized, ir is only now that this field has finally been shown microwave processing of ceramics. ‘I’hc interaction bet\\uzii
to be at the take-off stage. Although microwave heating microwa\xs and matter takes pl;tce through rhc electric field
~3s conceived 01 er SO years ago, its use iii ceramic pro- \‘ector and magnetic field vector of the elccrromagnctic ticld
cessing is relatively ne\\; Among the most prominent of the microwaves and in\& es polarization and conduction
advances in the past year were those reporwd on tungsten processes. (Iassically \xrious absorption mechanisms ha\ c
carbide (Il’C-based ceramic composites, fabrication of been identified in the interaction of niicronx\w with in;i1-
transparent ceramics, sintering of powdered metals and the ter. Exanplcs of these are dipole reorientation, conduction
design of a continuous microwave system to enable the of space and ionic charge. and so on, which are primaril)
commercialization of the technology. found in insulators or dielectric materials. Other energ? Ioss-
es, depending on the material under interaction. can occur
hlicrowave heating is fundamentally different from COII- through rlcctric conduction in (semi)metals and/or magnct-
ventional heating. Microwaves arc electromagnetic radia- ic resonance in magnetic materials. All these processes gi1.c
tion with waxlengths ranging from 1 mm to 1 m in free rise to energy losses which manifest themschzs in the form
space with a frequency between 300 GHz to 300 hIHz, of \dumetric heat in the material.
respectively. Today microwa\w at the 2.45 C;Hz frecluen-
c); arc used almost universally for industrial and scientif- Interest and activity in microwa\~e processing has been coii-
ic applications. In the microwave process, the heat is tinuously increasing, and the ~1st:of microuwx tcchnolog)
generated internally Mithin the material instead of origi- in industrial applications is also growing \vith nt‘n~ de\~lop-
nating from exwrnal sources, and hence there is an mats in both the engineering and design of micro\va\x sys-
inverse heating profile. ‘I’he heating is very rapid as the terns. ‘I’his growing and renewed interest in microux\ c
material is heated by energy con\wsion rather than by technology has been amply supported by the s~~cccss of the
Microwave processing of ceramics Agrawal 481
Figure 1 Table 1
Microwave Conventional
Powdered metals
As has been stated in earlier reviews the use of microwave
heating and sintering has been confined mainly to oxide Cment Opinion in Solid State & MaQeti& Scante
ceramics, and only recently has it been extended to car-
bide semimetals. But the most recent application of
Transparent ceramics. Top: transparent hydroxyapatite ceramics
microwave technology to another completely unexpected
fabricated in ambient air by microwave processing for 5 minutes at
area, yet one which encompasses a vast industry of variety 1100-l 150°C. Bottom: mullite ceramics sintered by microwave
of applications, namely powdered metals (PMs), has great processing for 10 minutes at 13OO’C.
significance [24’]. Bulk metals are excellent reflectors in
microwaves and in general are not heated significantly. But
in a powdered and unsintered form virtually all metals, Zeolites are important materials as catalysts, adsorbents
alloys, and intermetallics will couple/heat in a microwave and ion-exchangers. Querol et al. [ZS] have reported a rapid
field both very efficiently and effectively to produce high- method for recycling fly ash and synthesizing zeolites using
ly sintered bodies with improved mechanical properties. It a microwave assisted hydrothermal method. They used an
is reported that the microwave sintering of PM green bod- alkaline activation experiment and synthesized various
ies comprising various metals and metal alloys (Fe-Ni-C types of zeolitic material. They found that the activation
and Fe-Cu-C) has produced highly sintered bodies in a time was drastically reduced from 24-48 hours (by conven-
very short period of time. Typically the total cycle time was tional methods) to only 30 min using microwaves. In anoth-
-90 minutes, the sintering temperature ranged between er study Kosslick et ai. [26] prepared a series of zeolites
llOO”C-1300°C and the soaking time from 5 to 60 min- (aluminosilicates, aluminophosphates, etc.) and found that
utes. The mechanical properties, such as the modulus of the synthesis time decreased from the hours and days nor-
rupture (MOR) and hardness of microwave processed sam- mally needed in conventional methods to a few minutes.
ples were much higher than those of the conventionally They also claimed that in the case of an ion-exchange reac-
prepared samples. The densities of the microwave tion, the isomorphous replacement was enhanced and the
processed samples were also better than those of conven- quality of products was considerably improved. Microwave
tional samples. sintering of clay ceramics is also getting attention. Shiming
and McColm [27] studied clays with the addition of metal
Other developments and semiconducting powders as microwave coupling aids,
In addition to the above mentioned recent developments and achieved harder and stronger microwave sintered clay
in the field, there were a few minor but important areas in samples compared with conventional samples. Tan et al.
which microwaves were utilized and some significant [28] studied the phase transformation kinetics of four baux-
progress has been made in many on-going research areas. ite materials in a variable frequency microwave furnace,
484 Ceramics, composites and intergrowths
they quantitatively identified mullite, corundum and unpublished data) reported microwave sintering of
cristobalite phases in the fired extrudatcs. nanophase \1’(:/Co composites and stated that micron-;I\ c
sintered material exhibitcd higher hardness and finer ,qrain
‘I’hc technology of micrown~e drying has been in use for size than the conventionally sintered material. \‘ollath [-lo]
many years in channel dryers \vith com~eyor belts, especial- has developed a continuous process for synthesizing ccram-
ly for tableware products. Hut recently at Riedhammer ic nsnoparticles and nanocomposites of oxides. nitrides. sul-
(Germany; [29]) large micro\vave dryers have been LISC~ in fides, selenides and with certain precautions e\‘en carhidcs
drying technical ceramics, such as honeycomb structures and metals. ‘l’he author reported that, in general, it MX dif-
and insulators, with the advantage of energy savings and ;1 ficult to obtain a uniform distribution of t\zv or more phas-
uniform rapid drying. ‘I’hey claim damage-free drying of es when producing nanocomposites. Ilo\vwer. in the
items of large volume in microwaves in hours in contrast to microu~ave plasma process, the second phase is used to coat
weeks required by comrentional drying methods. ‘I’his is particles consisting of the first phase. this coating can IX ;I
one major area in ceramic processing where microaw.es second ceramic phase or a polymer.
have been successfully exploited for a commercial appli~:l-
tion. Sizgek and Sizgck [.30] ha1.e also reported the Conclusions
microwave drying characteristics of simulated high level licl- In the past year and half. significant df32lopments and
uid waste impregnated Synroc ceramic microsphcres. ‘I’hey advances ha\.e taken place in the field of microu.avc pro-
observed that at a given microwa\.e power le\cl, drying of cessing of ceramics. ‘I’hc microwave process is increasing-
water-saturxed samples was quicker and prod wed a homo- ly being exploited to develop better and cheaper products,
gencous distribution of the \uste than with comw&c dry- particularly specialty ceramics. It has hecn demonstrated
ing, which resulted in segregation of waste components. that in the case of \T:C/(:o the use of microwa\u can
reduce the cycle time to about one-tenth that required 11)
Several studies of the miorowavc sintering and microstruc- con\ entional means, and still obtain better propcrtics. ‘1%~
tural imestigations of zirconia based composites [.31-.X3) ad\antage of using microwaves was quite dramatic \\.licii
have been reported. In all of these studies an enhanced den- using redrlccd oxide precursors in synthesizing titanate
sification in the microwa\,e processed materials wxs and tantalate bawd electroccramics. ‘I’he microwa\c COII-
observed. Si,iN_, ceramics, which are widely used for high pling in the praence of :I defect strwturc causes cxtrcme-
temperature structural applications, were also f&ricated b> ly rapid reaction kinetics and new reaction paths producing
micro\\a\x methods and their microstructllral characteristics materials at much lower temperatures than normalI~-
examined [34,35]. The formation of a P-phase, which is very obtained by a comzntional heating method. ‘l’he most six-
critical for high toughness, was enhanced in microwaves. nificant dc\,elopmcnt in microwave sintcring has hxii the
Fiore and Clark [.%I reported a microwave induced rcduc- sintering of powdered metals and fabrication of transparent
tion/oxidation method to form ceramic-metal composites. ceramics in a single step process. ‘I’he so-called micro\52\ e
In a pressurcless microwave sintcring (371 method function- effect, which is commonly assumed to IX a nonthcrmal
al gradient material (I:GRl) of metal-ceramic compositions phenomenon and responsible for the rapid dcnsification
have been successfull\- fabricated and enhanced sintcring mechanisms has hccn explained
by the concentration of electrical energy in the ~loscd
t&searchers have been long discussing how to find out the pores of the green ceramics. It can be prcdictcd uith thcsc
exact nature of the so-called ‘micro\~a~e-effect’, which significant advances having been made in the field of
enhances the sinterability of the ceramics and other posi- niicrowri\.e processing of ceramics. that there is a great
tive effects observed during microwave processing of future for microwave technology for the swccssful con-
materials. In an excellent article DXllert-Porada [W] has mercialization for specialty- ceramics.
explained the micro\vavc effect hypothesis b); studying the
microstnlctural changes in the ceramics sintered by both References and recommended reading
Papers of particular interest, published within the annual period of review,
conventional and microwave methods. It w;ls cxplaincd
have been highlighted as:
that in that presence of an electric field (micravavc) the
l of special Interest
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