Lead-free potassium sodium niobate piezoceramics for high-power ultrasonic cutting application: Modelling and prototyping

Abstract

The motivation of this study was design, fabrication and characterization of bolt-clamped Langevin type transducers (BLT) from lead-free K 0.5 Na 0.5 NbO 3 (KNN) based piezoceramics for high-power ultrasonic cutting applications. Hard and lead-free KNN piezoceramics was obtained by adding K 4 CuNb 8 O 23 (KCN) together with ZnO and SnO 2 . Densification and high-power characteristics of KNN-KCN piezoceramics were enhanced in the presence of ZnO and SnO 2 . BLTs made from hard PZT4 (commercial Pb(Zr,Ti)O 3 ) or Zn,Sn co-doped KNN-KCN piezoceramic rings (KNN-KCN-ZnSn) were modelled through ATILA finite element analysis software package. Simulated and experimentally measured impedance spectra, resonance modes and harmonic analysis results of BLTs were compared with each other. Longitudinal vibration displacement at the tip of the horns of BLTs at approximately 30 kHz was measured via photonic sensor device to compare their performances. At the end, based on the simulation and experimental results, a prototype ultrasonic cutting device was fabricated from lead-free KNN-KCN-ZnSn piezoceramic rings. Its cutting action on both plastic and ceramic materials was demonstrated for the first time. In summary, it was found that a hard KNN-KCN based lead-free piezoceramics were good potential replacements for their lead-based counterparts for commercial high-power BLT applications.

Weight Loss during Calcination and Sintering Process of Na0.5Bi0.5TiO3–Bi1/2(Mg2/3Nb1/3)O3 Composite Lead-Free Piezoelectric Ceramics

“…Nonetheless, evaporation related to the hazardous nature of PbO during hightemperature sintering not only leads to ecological pollution, but also triggers variability of the composition and electrical characteristics of material [2,3]. Consequently, researchers around the world are focused on the synthesis of green lead-free piezoelectric ceramics to eliminate the hazardous lead oxide-based ceramics [4]. The research on lead-free piezoceramics has already started a new journey to replace lead zirconium titanate (PZT) with nonharmful choices [5].…”