Protocol for Ultralow-Temperature Ceramic Sintering: An Integration of Nanotechnology and the Cold Sintering Process

ZrW2O8/ZrO2 Composites with Low/Near-Zero Coefficients of Thermal Expansion Fabricated at Ultralow Temperature: An Integration of Hydrothermal Assembly and a Cold Sintering Process

ZrW₂O₈/ZrO₂ composites with tunable low/near-zero coefficients of thermal expansion (CTE) are promising candidates in several fields including aerospace, precision manufacturing and measurement, electronic circuit, etc., for counteracting the thermal expansion effect. However, bottleneck issues (such as the unstable decomposition of ZrW₂O₈ phase, manufacturing size limitation, etc.) caused by conventional high-temperature sintering impede the development and application of ZrW₂O₈/ZrO₂. To solve these scientific issues, a methodology integrating hydrothermal assembly with a cold sintering process (CSP) is exploited. The ZrW₂O₈/ZrO₂ composite powders with a mace-like structure, in which the spherical ZrO₂ nanoparticles peripherally embed on the rod-like ZrW₂O₈ matrix particles, are hydrothermally assembled. Then, the relatively dense ZrW₂O₈/ZrO₂ composites with excellent low or even near-zero CTE are successfully achieved by CSP (as low as 190 °C) with a postannealing treatment (550 °C). The evolution of sintering densification, phase composition, and microstructure followed by the fundamental mechanism regarding the hydrothermal assembly of the mace-like structure and densification of CSP are investigated in detail. This research not only effectively overcomes the bottleneck issues of ZrW₂O₈/ZrO₂ via integrating the hydrothermal assembly with the sintering technology at ultralow temperature but also develops a promising prospect for the fabrication of a broader range of metastable functional materials.

Comparative Study of Cold Sintering Process and Autoclave Thermo-Vapor Treatment on a ZnO Sample

Analysis of scanning electron microscopy images was used to study the changes in the crystal size distribution of ZnO, which occurred during its processing in an aqueous medium at 220–255 °C and an equilibrium vapor pressure in an autoclave. The results were compared with those of ZnO placed in a die for treatment under similar conditions supplemented with mechanical pressure application in the cold sintering process. In both cases, ZnO was treated in the presence of an activating additive: either zinc acetate or ammonium chloride. During autoclaving, a powder consisting of fine ZnO monocrystals was obtained, while the cold sintering process led to ceramics formation. Under vapor pressure and mechanical pressure, the aqueous medium affected ZnO transformation by the same mechanism of solid-phase mobility activation due to the additives’ influence. The higher the content of additives in the medium, and the higher the mechanical pressure, the more pronounced activating effect was observed. Mass transfer during the cold sintering process occurred mainly by the coalescence of crystals, while without mechanical pressure, the predominance of surface spreading was revealed. In the initial ZnO powder, the average crystal size was 0.193 μm. It grew up to 0.316–0.386 μm in a fine-crystalline powder formed in the autoclave and to an average grain size of 0.244–0.799 μm in the ceramics, which relative density reached 0.82–0.96. A scheme explaining the influence of an aqueous medium on the solid-phase mobility of ZnO structure was proposed. It was found that the addition of 7.6 mol% ammonium chloride to the reaction medium causes the processes of compaction and grain growth similar to those observed in ZnO Cold Sintering Process with the addition of 0.925 mol% zinc acetate.

Crystallization Behavior of the Low-Temperature Mineralization Sintering Process for Glass Nanoparticles

Bioactive glasses are promising materials for various applications, such as bone grafts and implants. The development of sintering techniques for bioactive glasses is one of the most important ways to expand the application to biomaterials. In this paper, we demonstrate the low-temperature mineralization sintering process (LMSP) of glass nanoparticles and their crystallization behavior. LMSP is a novel process employed to densify glass nanoparticles at an extremely low temperature of 120 °C. For this new approach, the hydrothermal condition, mineralization, and the nanosize effect are integrated into LMSP. To induce mineralization in LMSP, bioactive glass nanoparticles (BGNPs, 55SiO2-40CaO-5P2O5, mol%), prepared by the sol-gel process, were mixed with a small amount of simulated body fluid (SBF) solution. As a result, 93% dense BGNPs were realized under a temperature of 120 °C and a uniaxial pressure of 300 MPa. Due to the effect of mineralization, crystalline hydroxyapatite (HAp) was clearly formed at the boundaries of BGNPs, filling particles and interstitials. As a result, the relative density was remarkably close to that of the BGNPs conventionally sintered at 1050 °C. Additionally, the Vickers hardness value of LMSP samples varied from 2.10 ± 0.12 GPa to 4.28 ± 0.11 GPa, and was higher than that of the BGNPs conventionally sintered at 850 °C (2.02 ± 0.11 GPa). These results suggest that, in addition to LMSP being an efficient densification method for obtaining bulk bioactive glasses at a significantly lower temperature level, this process has great potential for tissue engineering applications, such as scaffolds and implants.

Current understanding and applications of the cold sintering process

In traditional ceramic processing techniques, high sintering temperature is necessary to achieve fully dense microstructures. But it can cause various problems including warpage, overfiring, element evaporation, and polymorphic transformation. To overcome these drawbacks, a novel processing technique called “cold sintering process (CSP)” has been explored by Randall et al. CSP enables densification of ceramics at ultra-low temperature (⩽300°C) with the assistance of transient aqueous solution and applied pressure. In CSP, the processing conditions including aqueous solution, pressure, temperature, and sintering duration play critical roles in the densification and properties of ceramics, which will be reviewed. The review will also include the applications of CSP in solid-state rechargeable batteries. Finally, the perspectives about CSP is proposed.

Insight into the Microstructure and Ionic Conductivity of Cold Sintered NASICON Solid Electrolyte for Solid-State Batteries

Li_1.3Al_0.3Ti_1.7(PO₄)₃ (LATP) is a popular solid electrolyte used in solid-state lithium batteries due to its high ionic conductivity. Traditionally, the densification of LATP is achieved by a high-temperature sintering process (about 1000 °C). Herein, we report the compaction of LATP by a newly developed cold sintering process and post-annealing. LATP pellets are first densified at 120 °C and then annealed at 650 °C, yielding an ionic conductivity of 8.04 × 10^-5 S cm^-1 at room temperature and a relative density of 93% with a low activation energy of 0.37 eV. High-resolution transmission electron microscopy of the cold sintered pellets is investigated as well, showing that the particles are interconnected with some nanoprecipitates at the grain boundaries. Such nanocrystalline-enriched grain boundaries are beneficial for lithium-ion transportation, which leads to higher ionic conductivity of the cold sintered sample. This new sintering process can direct new horizons for development of all solid-state batteries due to its simplicity.