Lead-Free Ceramics in Prestressed Ultrasonic Transducers

Today’s ultrasonic transducers find broad application in diverse technology branches and most often cannot be replaced by other actuators. They are typically based on lead-containing piezoelectric ceramics. These should be replaced for environmental and health issues by lead-free alternatives. Multiple material alternatives are already known, but there is a lack of information about their technological readiness level. To fill this gap, a small series of prestressed longitudinally vibrating transducers was set up with a standard PZT material and two lead-free variants within this study. The entire process for building the transducers is documented: characteristics of individual ring ceramics, burn-in results, and free vibration and characteristics under load are shown. The main result is that the investigated lead-free materials are ready to use within ultrasonic bolted Langevin transducers (BLTs) for medium-power applications, when the geometrical setup of the transducer is adopted. Since lead-free ceramics need higher voltages to achieve the same power level, the driving electronics or the mechanical setup must be altered specifically for each material. Lower self-heating of the lead-free materials might be attractive for heat-sensitive processes.