Free standing sintered ceramic films from electrophoretic deposition

The fabrication of free standing ceramic films approximately 10 μm has been demonstrated using electrophoretic deposition on a polished substrate with a fugitive graphite electrode. Electrophoretic deposition allows a homogeneous powder bed to be obtained with green densities approximately 55 to 60% of theoretical density. The graphite interlayer first acts as the electrode and then on sintering is removed, therefore providing only a weakly bonded interface. The deposit undergoes sintering under unconstrained conditions, owing to the poor adhesion; then on cooling the thermal expansion mismatch leads to free standing films.