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<p>A nacre-inspired flake alumina/BABS glass composite was designed for LTCC applications to achieve the synergistic optimization of dielectric, thermal, and mechanical properties. Flake alumina (10–30 wt%) was incorporated into the BABS glass matrix via tape casting, forming a preferentially aligned “brick-and-mortar” structure. The effects of flake alumina content on crystallization behavior, sintering densification, microwave dielectric properties, thermal expansion, and mechanical performance were systematically investigated. The results show that flake alumina alignment does not alter the primary crystalline phases: Ba<sub>0.5</sub>Sr<sub>0.5</sub>Al<sub>2</sub>Si<sub>2</sub>O<sub>8</sub> and CaMgSi<sub>2</sub>O<sub>6</sub> but induces a crystallization-related “step” behavior that affects density evolution, microwave dielectric properties, and thermal expansion. Microwave dielectric measurements at 10&#xa0;GHz indicate that the composites exhibit dielectric constants below 8 and dielectric losses on the order of 10<sup>−3</sup>, depending on filler content and sintering temperature. The composites exhibit coefficients of thermal expansion in the range of approximately 6.5–7.5&#xa0;ppm/℃. Meanwhile, sintering near the crystallization temperature enables moderate crystallization, stabilizing the glass structure and mitigating porosity-induced density reduction. Benefiting from synergistic crack deflection and strong interfacial bonding, the composites exhibit markedly enhanced mechanical performance, with flexural strengths exceeding 250&#xa0;MPa and elastic moduli above 125 GPa at 30 wt% flake alumina. This work provides an effective design strategy for developing high-strength, low-loss LTCC materials suitable for high-frequency applications.</p>

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Flake alumina-reinforced BABS glass composite for LTCC: synergistic enhancement of microstructure and mechanical properties

  • 期刊论文

  • 发表日期：

    2026年7月9日

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  • Zhengnan Shi,
  • Tianyi Xie,
  • Fancheng Meng,
  • Yanbin Xiong,
  • Huixing Lin,
  • Haishen Ren

摘要

A nacre-inspired flake alumina/BABS glass composite was designed for LTCC applications to achieve the synergistic optimization of dielectric, thermal, and mechanical properties. Flake alumina (10–30 wt%) was incorporated into the BABS glass matrix via tape casting, forming a preferentially aligned “brick-and-mortar” structure. The effects of flake alumina content on crystallization behavior, sintering densification, microwave dielectric properties, thermal expansion, and mechanical performance were systematically investigated. The results show that flake alumina alignment does not alter the primary crystalline phases: Ba0.5Sr0.5Al2Si2O8 and CaMgSi2O6 but induces a crystallization-related “step” behavior that affects density evolution, microwave dielectric properties, and thermal expansion. Microwave dielectric measurements at 10 GHz indicate that the composites exhibit dielectric constants below 8 and dielectric losses on the order of 10−3, depending on filler content and sintering temperature. The composites exhibit coefficients of thermal expansion in the range of approximately 6.5–7.5 ppm/℃. Meanwhile, sintering near the crystallization temperature enables moderate crystallization, stabilizing the glass structure and mitigating porosity-induced density reduction. Benefiting from synergistic crack deflection and strong interfacial bonding, the composites exhibit markedly enhanced mechanical performance, with flexural strengths exceeding 250 MPa and elastic moduli above 125 GPa at 30 wt% flake alumina. This work provides an effective design strategy for developing high-strength, low-loss LTCC materials suitable for high-frequency applications.