High-Performance Curved Piezoelectric Single-Crystal Composites via 3D-Printing-Assisted Dice and Insert Technology for Underwater Acoustic Transducer Applications

Piezoelectric single-crystal composites (PSCCs) have been studied and applied because of their improved resolution and power source level performance in underwater acoustic transducer applications relative to traditional piezoelectric ceramic composites (PCCs). Currently, the methods to fabricate curved PSCCs are mostly derived from PCCs, including molding with flexible backing, molding with heating, and molding with the casting rubber method. Unfortunately, the methods mentioned above are not suitable for preparing curved PSCCs for underwater acoustic transducer applications because of their brittleness, the large anisotropy of piezoelectric single crystals, and the high thickness (>2 mm) of PSCCs for achieving the low operating frequency (<700 kHz). In the present work, we proposed a preparation method, 3D-printing-assisted dice and insert technology, and successfully prepared curved PSCCs with high performance. Although the PSCCs have a low volume fraction of single crystals in this work (similar to 33%), a high thickness electromechanical factor k(t) of 86% and a large piezoelectric coefficient d(33) of 1550 pC/N were achieved in the curved 1-3 PSCCs, which are superior to other reported PSCCs and PCCs with nearly the same volume fraction of single crystals and piezoelectric ceramics. This work presents a paradigm for fabricating curved PSCCs for underwater acoustic transducers, and this method shows the potential for large-area, special-shaped PSCCs, which are key materials for next-generation underwater acoustic transducers.