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Abstract

A net-shape process for fabricating a fully dense ceramic preform for a piezoelectric or electrostrictive composite transducer exhibiting 1-3 or 2-2 connectivity. The process involves preparing a homogeneous, granulated, thermoplastic powder/binder mixture from a strongly piezoelectric or electrostrictive ceramic material powder and a thermoplastic organic binder selected to be nondestructively removed from the mixture by heating. The mixture is injection molded to form a self-supporting green body including a planar ceramic base with parallel ceramic elements extending perpendicularly from the base in a preselected array. Each element has a rod-like or lamellar shape. The body is released from the preform mold, heated to a temperature of 300.degree.-700.degree. C. for a time sufficient to completely remove the binder, and sintered to at least about 95% of theoretical density. To fabricate a piezoelectric or electrostrictive composite transducer exhibiting 1-3 or 2-2 connectivity and including a fully dense piezoelectric or electrostrictive ceramic phase, the preform is encapsulated in a polymeric material to form a 2-phase ceramic/polymer composite. The ceramic base is removed from the lower planar surface of the composite and the elements are exposed at each of the upper and lower planar surfaces. The composite is electroded to establish electrical contact with the elements. The elements may be poled to produce a piezoelectric composite transducer exhibiting 1-3 or 2-2 connectivity.

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