Morphological and chemical evolution of transient interfaces during zinc oxide cold sintering process

Although zinc oxide has a high melting point of 1975 °C, the recent development of the cold sintering process has shown that highly dense polycrystalline ceramics can be obtained at 150 °C or below. As such unusual densification does not yet have fully elucidated underlying mechanisms, this study aims to provide a comprehensive investigation of transient morphological and chemical interfaces during isothermal dwell. The chemical “transient” interface involves the formation of a zinc carboxylate complex by reacting the host zinc oxide powder and acetic acid solution, which is later consumed for the recrystallization on the lattice of an adjacent grain with a decomposition of the complex. Hence, the final outcome can be a residual-free zinc oxide phase. Regarding the morphological evolution, gas physisorption studies were conducted to quantify the area of solid–vapor interfaces and the Schlaffer model was used to analyze the activation energy for specific surface area reduction. Moreover, transmission electron micrographs revealed that the recrystallization occurs at the interface between crystalline grain and carbon-rich amorphous phase. After 30 minutes of isothermal dwell, the area of the amorphous phase was significantly decreased while grain size was increased, potentially indicating the recrystallization-induced grain growth and pore closure. The chemical transition at the zinc oxide surface was further investigated using ReaxFF molecular dynamics simulation, observing that acetate molecule acts as a bridging complex to connect zinc ions to the surface. Overall, understanding the evolution of the transient interface is a crucial subject to obtaining a residual-free cold-sintered sample with desired grain size and properties for application developments.