Making the Case for Scaling Up Microwave Sintering of Ceramics

Abstract

The densification and sintering of ceramics using microwaves is first reported in the mid‐1960s. Today, the reduced carbon footprint of this process has renewed interest as it uses less energy overall compared to conventional process heating/furnaces. However, scaling up and commercializing the microwave sintering process of ceramics remains a formidable challenge. As a contactless method, microwave sintering offers geometric flexibility over other field‐assisted sintering processes. Yet, the inability to address multiscale, multiphysics‐driven heterogeneities arising during microwave coupling limits discussions about a future scale‐up process. Herein, the case is made that unlike 60 years ago, new advances in multiscale computational modeling, materials characterization, control systems, and software open up new avenues for addressing these challenges. More importantly, the rise of additive manufacturing techniques demands the innovation of sintering processes in the ceramics community for realizing near‐net‐shaped and complex parts for applications ranging from medical implants to automotive and aerospace parts.