Research on material jetting fabrication and dielectric constant calculation of LTCC based on silica-borosilicate glass

Abstract

Several material systems are available for low-temperature co-fired ceramics, and to achieve more efficient designs and applications using additive manufacturing (AM) techniques such as material jetting, the predictability of the dielectric constant of the sintered structure will significantly reduce the consumption of material development. In this work, the LTCC part was fabricated by 3D material jetting using silica-borosilicate glass LTCC ink and densified at 850°C. The borosilicate glass composition was derived from nanopowders prepared by radio frequency plasma spheronisation and configured as surface-grafted glass sols. Scanning electron microscopy results showed that silica particles were embedded in the glass matrix by a liquid phase sintering mechanism accompanied by several confined pores that were difficult to remove. A dielectric constant of around 3.78 was tested from room temperature to 100°C. Molecular dynamics sintering simulation was used to create sintered structures that matched the experimental values. The dipole moment fluctuation of the silica/glass bulk was counted to obtain an accurate value of the dielectric constant, and then the Bruggeman model based on the effective medium theory predicted the dielectric constant of the sintered body, with a prediction of 3.65, which is within 4 % difference from the measured value (3.78). The dielectric constant was predicted for different ceramic/glass compositions and sintering temperatures and found that 35 wt% and 60 wt% should be the upper and lower bounds for borosilicate glass additions to satisfy a stable structure with a relatively low dielectric constant range (3.38–4.42). In conclusion, an effective molecular dynamics approach to predict the dielectric constant of sintered bodies was developed to assist material design in LTCC AM fabrication.