Porous oxide ceramics are widely used in extreme working conditions owing to their excellent resistance to high temperatures and corrosion. However, sintering is an inevitable process applied to ceramics, from the green body to the final product. The highly complex structures exacerbate the shrinkage-induced irregular deformation and crack formation in the sintering process. A pioneering approach is developed in this study to achieve zero shrinkage for porous alumina ceramics during multistep sintering, using a combination of active fillers - ZrAl₃ and Al₇₅Si₂₅. The response surface method is used to optimize the material compositions and sintering process, to achieve shrinkages of less than 0.05% for the entire process. The sintering expansion mechanism is investigated by analyzing the pyrolysis and microstructures of samples at different temperatures. The combination of ZrAl₃ and Al₇₅Si₂₅ can attain the continuous expansion of the matrix in a wide temperature range of 600–1400 °C. Furthermore, typical alumina components are fabricated and used to verify the effectiveness of the proposed approach. Owing to shrinkage suppression, the profile deviation of the samples is less than 0.1 mm, and the proportion of microcracks is reduced by 97.8%. The suggested approach shows potential applications in near-net, low-defect fabrication of complex fine ceramic components.

多孔氧化物陶瓷以其优异的耐高温和耐腐蚀性能广泛应用于极端工作条件下。然而，烧结是应用于陶瓷的必然过程，从生坯到最终产品。高度复杂的结构加剧了烧结过程中收缩引起的不规则变形和裂纹的形成。本研究开发了一种开创性的方法，使用活性填料 ZrAl 3 和_Al 75 _Si 25_{的组合，在多步烧结过程中实现多孔氧化铝陶瓷的零收缩}. 采用响应面法优化材料成分和烧结工艺，实现全过程收缩率小于0.05%。通过分析样品在不同温度下的热解和微观结构，研究了烧结膨胀机理。_{ZrAl 3}与Al ₇₅ Si ₂₅的组合可以在600-1400°C的宽温度范围内实现基体的连续膨胀。此外，还制造了典型的氧化铝组件并用于验证所提出方法的有效性。由于收缩抑制，样品的轮廓偏差小于0.1 mm，微裂纹比例降低了97.8%。建议的方法显示了在复杂精细陶瓷部件的近净、低缺陷制造中的潜在应用。