Exploring the Mpemba effect: a universal ice pressing enables porous ceramics

Piezoceramics with global porosity and local compaction are highly desired to exploit the combination of mechanical and electrical properties. However, achieving such a functional combination is challenging because of the lack of techniques for applying uniform pressure inside porous ceramic green parts. Nature provides many examples of generating strong forces inside the macro and micro channels via the state transformation of water. Inspired by these phenomena, we present a technique of "ice and fire", that is, water freezing (ice pressing) and high-temperature sintering (fire), to produce ideal porous piezoceramics. We introduce a new compaction method called the "ice pressing method", which manipulates liquid phase transition for compaction. This method has several advantages, including uniform pressure distribution, a wide pressure range, high effectiveness, and selective freezing. It can generate an ultrahigh pressure of up to 180 MPa on the piezoceramic green skeletons in minutes while retaining their functional pore structures. By exploiting the Mpemba phenomenon, we further accelerate the compaction procedure by 11%. The first ice-pressed and second fire-consolidated lead zirconate titanate (PZT) ceramics are highly densified and exhibit an outstanding piezoelectric response (d₃₃ = 531 pC N^-1), comparable to conventional pressed bulk counterparts and 10-20 times higher than those of unpressed materials. The novel ice pressing method breaks the limitation of lacking a compaction technique for porous ceramics. The versatile and effective ice pressing method is a green and low-cost route promoting applications in sensors, acoustics, water filtration, catalyst substrates, and energy harvesting.