Rapid microwave sintering of zinc oxide-based varistor ceramics

Abstract Samples of ZnO + Bi2O3 + Sb2O3 varistor ceramics were microwave sintered using gyrotron systems operating at a frequency of 24 GHz. The microwave power was automatically regulated to implement heating at a constant heating rate of 10–130 °C/min up to a temperature of 1100–1300 °C with no isothermal hold. The final sintered density of the samples was 95–96 % of the theoretical value. Manifestations of the thermal instability associated with the liquid phase formation were observed at a temperature of about 600 °C. The estimated volumetrically absorbed power density at the onset of instability was ≥20 W/cm3, and the temperature difference measured between the center and periphery of the samples reached 200 °C. Correlation has been revealed between the thermal instability occurrence and the shift of densification curves towards lower temperatures. A mechanism underlying enhanced densification in electromagnetic field-assisted sintering processes is suggested.