Both structural and functional devices are so close to the optimum efficiencies that only marginal gains in specific performances could be expected with conventional powder processing techniques, even with very-complex designs. Improving a variety of performances and enabling the design of new devices can be done, but requires the use of new materials technology. This presentation will focus on the melt processing of ceramics using the melt modulation technique.

    The melt modulation technique promises a leap forward in terms of future structural and functional ceramic capabilities because it enables the growth of a new class of materials. The solidification characteristics of oxides from the trigonal crystal system (sapphire and ruby), from the cubic system (garnet crystals and rare earth oxides) and from the orthorhombic system (mullite) will be presented. The solidification characteristics of wide range of oxide ceramics eutectics and their relation to achieve in-situ composites materials will be treated at some length. The properties of two-phase eutectic ceramics can be superior to that of either constituent alone due to the strong constraining effects of the interlocking microstructure. Examples will be presented to reveal the application of this technology to produce high temperature actuator ceramics using perovskite family crystal classes. New functional ceramics produced from perovskite family of crystal structures for protonic conductance will be explained and its relevance to the hydrogen economy will be described.