Simplified Single-Step Fabrication of Composite Transparent Ceramics

Composite transparent ceramics offer various advantages over monolithic parts in many photonic applications. Typically, the formation of multicomponent composites requires elaborate processes that involve multiple steps of green body preparation and densification. This study presents a straightforward single-step fabrication method for composite transparent ceramics using spark plasma sintering. The method utilizes customized compaction tools that enable specific powder arrangements within the graphite die, resulting in a configured green body that can be directly densified. The versatile yet simple process is demonstrated for various composite designs, primarily comprising Nd³⁺:YAG and undoped YAG. The high transparency and precision of these composite ceramics render them suitable for prospective optical components such as high-power lasers and phosphors. Overall, the proposed method applies not only to multicomponent functional ceramics, but potentially any combination of sinterable materials, with similar densification behavior and thermal expansion coefficients.