This paper describes a smart and industrially suitable technique for prepar
ing a high performance ZnO varistor from doped zinc oxide powder. A homogen
eous distribution of various dopants in the mixed powder has been achieved
by coating ZnO powder with a mixed solution of dopants in the form of aceta
tes, nitrates and citrates. The mixed powder on subsequent drying, calcinat
ion. and sintering, produced varistors with better nonlinear electrical pro
perties (alpha = 51) compared to varistors prepared from conventional oxide
mixing technique (alpha = 30). The better nonlinear properties of solution
coating route varistors have been attributed to the presence of uniform po
tential barriers throughout the entire microstructure, which in turn is cre
dited to the uniform distribution of dopant ions at each grain and grain bo
undary region. (C) 2001 Elsevier Science Ltd. All rights reserved.