Observable Two-Step Nucleation Mechanism in Solid-State Formation of Tungsten Carbide

Understanding the nanoscale phenomena of nucleation and crystal growth in electrodeposition

Electrodeposition is used at the industrial scale to make coatings, membranes, and composites. With better understanding of the nanoscale phenomena associated with the early stage of the process, electrodeposition has potential to be adopted by manufacturers of energy storage devices, advanced electrode materials, fuel cells, carbon dioxide capturing technologies, and advanced sensing electronics. The ability to conduct precise electrochemical measurements using cyclic voltammetry, chronoamperometry, and chronopotentiometry in addition to control of precursor composition and concentration makes electrocrystallization an attractive method to investigate nucleation and early-stage crystal growth. In this article, we review recent findings of nucleation and crystal growth behaviors at the nanoscale, paying close attention to those that deviate from the classical theories in various electrodeposition systems. The review affirms electrodeposition as a valuable method both for gaining new insights into nucleation and crystallization on surfaces and as a low-cost scalable technology for the manufacturing of advanced materials and devices.

Resolving heterogeneous particle mobility in deeply quenched liquid iron: an ultra-fast assembly-free two-step nucleation mechanism

Despite intensive research, little is known about the intermediate state of phase transforming materials, which may form the missing link between e.g. liquids and solids on the nanoscale. The unraveling of the nanoscale interplay between the structure and dynamics of the intermediate state of phase transformations (through which e.g. crystal nucleation proceeds) is one of the biggest challenges and unsolved problems of materials science. Here we show using unbiased molecular dynamics simulations and spatially resolved atomic displacement maps (d-maps) that upon deep quenching the solidification of undercooled liquid iron proceeds through the formation of metastable pre-nucleation clusters (PNCs). We also reveal that the hitherto hidden PNCs are nearly immobile (dynamically arrested) and the related heterogeneity in atomic mobilities becomes clearly visible on atomic displacement-maps (d-maps) when atomic jumps are referenced to the final crystalline positions. However, this is in contrast to PNCs found in molecular solutions, in which PNCs tend to aggregate, move and crystallize via an activated process. Coordination filtered d-maps resolved in real space directly demonstrate that previously unseen highly ramified intermediate atomic clusters with a short lifetime emerge after incubation of undercooled liquid iron. The supercooled liquid iron is neither a spinodal system nor a liquid and undergoes a transition into a specific state called a quasi-liquid state within the temperature regime of 700-1250 K (0.5Tm > 0.7Tm, where the melting point is Tm ≈ 1811 K). Below 700 K the supercooled system is spinodal-like and above 1300 K it behaves like an ordinary liquid with long incubation times. A two-step process is proposed to explain the anomalous drop in the incubation time in the temperature regime of 700-1250 K. The 1st step is activated aggregation of small atomic clusters followed by assembly-free nearly barrierless ultrafast growth of early ramified prenucleation clusters called germs. The display and characterization of the hidden PNCs in computer simulations could provide new perspectives on the deeper understanding of the long-standing problem of precursor development during crystal nucleation following deep quenching.

Selective formation of metastable polymorphs in solid-state synthesis

Metastable polymorphs often result from the interplay between thermodynamics and kinetics. Despite advances in predictive synthesis for solution-based techniques, there remains a lack of methods to design solid-state reactions targeting metastable materials. Here, we introduce a theoretical framework to predict and control polymorph selectivity in solid-state reactions. This framework presents reaction energy as a rarely used handle for polymorph selection, which influences the role of surface energy in promoting the nucleation of metastable phases. Through in situ characterization and density functional theory calculations on two distinct synthesis pathways targeting LiTiOPO4, we demonstrate how precursor selection and its effect on reaction energy can effectively be used to control which polymorph is obtained from solid-state synthesis. A general approach is outlined to quantify the conditions under which metastable polymorphs are experimentally accessible. With comparison to historical data, this approach suggests that using appropriate precursors could enable targeted materials synthesis across diverse chemistries through selective polymorph nucleation.

Controlled Growth of Pd Nanocrystals by Interface Interaction on Monolayer MoS2: An Atom-Resolved in Situ Study

The crystal growth kinetics is crucial for the controllable preparation and performance modulation of metal nanocrystals (NCs). However, the study of growth mechanisms is significantly limited by characterization techniques, and it is still challenging to in situ capture the growth process. Real-time and real-space imaging techniques at the atomic scale can promote the understanding of microdynamics for NC growth. Herein, the growth of Pd NCs on monolayer MoS2 under different atmospheres was in situ studied by environmental transmission electron microscopy. Introducing carbon monoxide can modulate the diffusion of Pd monomers, resulting in the epitaxial growth of Pd NCs with a uniform orientation. The electron energy loss spectroscopy and theoretical calculations showed that the CO adsorption assured the specific exposed facets and good uniformity of Pd NCs. The insight into the gas-solid interface interaction and the microscopic growth mechanism of NCs may shed light on the precise synthesis of NCs on two-dimensional (2D) materials.

In situ TEM investigation of nucleation and crystallization of hybrid bismuth nanodiamonds

Despite great progress in the non-classical homogeneous nucleation and crystallization theory, the heterogeneous processes of atomic nucleation and crystallization remain poorly understood. Abundant theories and experiments have demonstrated the detailed dynamics of homogeneous nucleation; however, intensive dynamic investigations on heterogeneous nucleation are still rare. In this work, in situ transmission electron microscopy (TEM) at the atomic scale was carried out with temporal resolution for heterogeneous nucleation and crystallization. The results show a reversible amorphous to crystal phase transformation that is manipulated by the size threshold effect. Moreover, the two growth pathways of Bi particles can be mainly assigned to the atomic adsorption expansion in the amorphous state and effective fusion in the crystal contact process. These interesting findings, based on a real dynamic imaging system, strongly enrich and improve our understanding of the dynamic mechanisms in the non-classical heterogeneous nucleation and crystallization theory, providing insights into designing innovative materials with controlled microstructures and desired physicochemical properties.

Direct Observation of Off-Stoichiometry-Induced Phase Transformation of 2D CdSe Quantum Nanosheets

Crystal structures determine material properties, suggesting that crystal phase transformations have the potential for application in a variety of systems and devices. Phase transitions are more likely to occur in smaller crystals; however, in quantum-sized semiconductor nanocrystals, the microscopic mechanisms by which phase transitions occur are not well understood. Herein, the phase transformation of 2D CdSe quantum nanosheets caused by off-stoichiometry is revealed, and the progress of the transformation is directly observed by in situ transmission electron microscopy. The initial hexagonal wurtzite-CdSe nanosheets with atomically uniform thickness are transformed into cubic zinc blende-CdSe nanosheets. A combined experimental and theoretical study reveals that electron-beam irradiation can change the stoichiometry of the nanosheets, thereby triggering phase transformation. The loss of Se atoms induces the reconstruction of surface atoms, driving the transformation from wurtzite-CdSe(11 2 ¯ $\bar{2}$ 0) to zinc blende-CdSe(001) 2D nanocrystals. Furthermore, during the phase transformation, unconventional dynamic phenomena occur, including domain separation. This study contributes to the fundamental understanding of the phase transformations in 2D quantum-sized semiconductor nanocrystals.

In Situ Kinetic Observations on Crystal Nucleation and Growth

Nucleation and growth are critical steps in crystallization, which plays an important role in determining crystal structure, size, morphology, and purity. Therefore, understanding the mechanisms of nucleation and growth is crucial to realize the controllable fabrication of crystalline products with desired and reproducible properties. Based on classical models, the initial crystal nucleus is formed by the spontaneous aggregation of ions, atoms, or molecules, and crystal growth is dependent on the monomer's diffusion and the surface reaction. Recently, numerous in situ investigations on crystallization dynamics have uncovered the existence of nonclassical mechanisms. This review provides a summary and highlights the in situ studies of crystal nucleation and growth, with a particular emphasis on the state-of-the-art research progress since the year 2016, and includes technological advances, atomic-scale observations, substrate- and temperature-dependent nucleation and growth, and the progress achieved in the various materials: metals, alloys, metallic compounds, colloids, and proteins. Finally, the forthcoming opportunities and challenges in this fascinating field are discussed.

Dynamic Observation of Anisotropic Chainlike Structures during Nonclassical Two-Step Nucleation in Solid-State Iron Oxide Crystallization

The demonstration of the self-crystallization nucleation process from an amorphous precursor in a solid is crucial for understanding of interactions between atoms. We report a study of dynamic crystallization process of iron oxides by virtue of in situ measurement of transmission electron microscopy. At first, semiordered chainlike structures are observed with the increase of concentration, and when sufficient chains form, the crystalline lattice begins to grow. The two-step nucleation pathway has also been confirmed by performing a molecular dynamics simulation, where Lennard-Jones and magnetic dipole-dipole interaction potentials are both taken into account and take effect individually predominantly in different ranges of distance between atoms. Furthermore, the total free energy profile in the crystallization nucleation process is calculated to evidence the stabilization of intermediate state. This work advances our understanding of nonclassical nucleation theory.

Multistep nucleation visualized during solid-state crystallization

Mechanisms of nucleation have been debated for more than a century, despite successes of classical nucleation theory. The nucleation process has been recently argued as involving a nonclassical mechanism (the "two-step" mechanism) in which an intermediate step occurs before the formation of a nascent ordered phase. However, a thorough understanding of this mechanism, in terms of both microscopic kinetics and thermodynamics, remains experimentally challenging. Here, in situ observations using transmission electron microscopy on a solid-state nucleation case indicate that early-stage crystallization can follow the non-classical pathway, yet proceed via a more complex manner in which multiple metastable states precede the emergence of a stable nucleus. The intermediate steps were sequentially isolated as spinodal decomposition of amorphous precursor, mass transport and structural oscillations between crystalline and amorphous states. Our experimental and theoretical analyses support the idea that the energetic favorability is the driving force for the observed sequence of events. Due to the broad applicability of solid-state crystallization, the findings of this study offer new insights into modern nucleation theory and a potential avenue for materials design.

Atom-Resolved Investigation on Dynamic Nucleation and Growth of Platinum Nanocrystals

Understanding the mechanism of nucleation and growth of nanocrystals is crucial for designing and regulating the structure and properties of nanocrystals. However, the process from molecules to nanocrystals remains unclear because of the rapid and complicated dynamics of evolution under reaction conditions. Here, the complete evolution process of solid-phase chloroplatinic acid during the electron beam irradiation triggered reduction and nucleation of platinum nanocrystals is recorded. Aberration-corrected environmental transmission electron microscopy is used for direct visualization of the dynamic evolution from H₂ PtCl₆ to Pt nanocrystals at the atomic scale, including the formation and growth of amorphous clusters, crystallization, and growth of clusters, and the ripening of Pt nanocrystals. At the first two stages, there exists a critical size of ≈2.0 nm, which represents the start of crystallization. Crystallization from the center and density fluctuation are observed in the second stage of the crystallization of a few clusters with a size obviously larger than the critical size. The work provides valuable information to understand the kinetics of the early stage of nanocrystal nucleation and crystallization at atomic scale.

High Densification of Tungsten via Hot Pressing at 1300 °C in Carbon Presence

A reactive sintering technique with a small addition of carbon (up to 1.9 wt.%) has been used for tungsten powder consolidation. The process allowed procurement of the nonporous and fully densified material at 1300 °C and 30 MPa in 12 min. The SEM and EDX analysis showed that the milling of 5 μm tungsten powder with 0.6, 1.3, and 1.9 wt.% of carbon in a planetary mill led to the formation of the nanostructured mix, which appears to be W-C nanopowder surrounding tungsten grains. X-Ray Diffractometry data indicated tungsten hemicarbide (W₂C) nucleation during the hot pressing of the milled powders. The exothermic reaction 2W + C → W₂C occurs during the sintering process and promotes charge densification. The Vickers hardness and indentation toughness of W-1.3 wt.%C composition reached 5.7 GPa and 12.6 MPa∙m^1/2, respectively. High toughness and high material densification allow proposing the W-WC₂ for use as a plasma-facing material in fusion applications.

Heterointerface Effect on Two-Step Nucleation Mechanism of Bi Particles

The nucleation and crystallization of Bi particles on two matrices, crystalline bismuth sulfide (c-Bi₂S₃) and amorphized bismuth titanium oxide (a-Bi₁₂TiO₂₀), were studied by using in situ transmission electron microscopy (TEM) analysis. The atomic structures of the Bi particles were monitored by acquiring high-resolution TEM images in real time. The Bi particles were grown on c-Bi₂S₃ and a-Bi₁₂TiO₂₀ via a two-step nucleation mechanism; dense liquid clusters were clearly observed at the initial stage of nucleation, and the coalescence of clusters was frequently observed during the growth. However, the nucleation and crystallization behaviors of Bi particles were governed by the matrix; in particular, the evolution of their morphology and atomic structure was confined on c-Bi₂S₃ but free from matrix effects on a-Bi₁₂TiO₂₀. The matrix effect on the two-step nucleation mechanism was demonstrated from a thermodynamic point of view.

Atomic-scale observation of non-classical nucleation-mediated phase transformation in a titanium alloy

Two-phase titanium-based alloys are widely used in aerospace and biomedical applications, and they are obtained through phase transformations between a low-temperature hexagonal closed-packed α-phase and a high-temperature body-centred cubic β-phase. Understanding how a new phase evolves from its parent phase is critical to controlling the transforming microstructures and thus material properties. Here, we report time-resolved experimental evidence, at sub-ångström resolution, of a non-classically nucleated metastable phase that bridges the α-phase and the β-phase, in a technologically important titanium-molybdenum alloy. We observed a nanosized and chemically ordered superstructure in the α-phase matrix; its composition, chemical order and crystal structure are all found to be different from both the parent and the product phases, but instigating a vanishingly low energy barrier for the transformation into the β-phase. This latter phase transition can proceed instantly via vibrational switching when the molybdenum concentration in the superstructure exceeds a critical value. We expect that such a non-classical phase evolution mechanism is much more common than previously believed for solid-state transformations.

Visualization of Bubble Nucleation and Growth Confined in 2D Flakes

The nucleation and growth of bubbles within a solid matrix is a ubiquitous phenomenon that affects many natural and synthetic processes. However, such a bubbling process is almost "invisible" to common characterization methods because it has an intrinsically multiphased nature and occurs on very short time/length scales. Using in situ transmission electron microscopy to explore the decomposition of a solid precursor that emits gaseous byproducts, the direct observation of a complete nanoscale bubbling process confined in ultrathin 2D flakes is presented here. This result suggests a three-step pathway for bubble formation in the confined environment: void formation via spinodal decomposition, bubble nucleation from the spherization of voids, and bubble growth by coalescence. Furthermore, the systematic kinetics analysis based on COMSOL simulations shows that bubble growth is actually achieved by developing metastable or unstable necks between neighboring bubbles before coalescing into one. This thorough understanding of the bubbling mechanism in a confined geometry has implications for refining modern nucleation theories and controlling bubble-related processes in the fabrication of advanced materials (i.e., topological porous materials).

Recent Progress in Emerging Two-Dimensional Transition Metal Carbides

As a new member in two-dimensional materials family, transition metal carbides (TMCs) have many excellent properties, such as chemical stability, in-plane anisotropy, high conductivity and flexibility, and remarkable energy conversation efficiency, which predispose them for promising applications as transparent electrode, flexible electronics, broadband photodetectors and battery electrodes. However, up to now, their device applications are in the early stage, especially because their controllable synthesis is still a great challenge. This review systematically summarized the state-of-the-art research in this rapidly developing field with particular focus on structure, property, synthesis and applicability of TMCs. Finally, the current challenges and future perspectives are outlined for the application of 2D TMCs.

Reversible disorder-order transitions in atomic crystal nucleation

Nucleation in atomic crystallization remains poorly understood, despite advances in classical nucleation theory. The nucleation process has been described to involve a nonclassical mechanism that includes a spontaneous transition from disordered to crystalline states, but a detailed understanding of dynamics requires further investigation. In situ electron microscopy of heterogeneous nucleation of individual gold nanocrystals with millisecond temporal resolution shows that the early stage of atomic crystallization proceeds through dynamic structural fluctuations between disordered and crystalline states, rather than through a single irreversible transition. Our experimental and theoretical analyses support the idea that structural fluctuations originate from size-dependent thermodynamic stability of the two states in atomic clusters. These findings, based on dynamics in a real atomic system, reshape and improve our understanding of nucleation mechanisms in atomic crystallization.

Out-of-Equilibrium Polymorph Selection in Nanoparticle Freezing

The ability to design synthesis processes that are out of equilibrium has opened the possibility of creating nanomaterials with remarkable physicochemical properties, choosing from a much richer palette of possible atomic architectures compared to equilibrium processes in extended systems. In this work, we employ atomistic simulations to demonstrate how to control polymorph selection via the cooling rate during nanoparticle freezing in the case of Ni₃Al, a material with a rich structural landscape. State-of-the-art free-energy calculations allow us to rationalize the complex nucleation process, discovering a switch between two kinetic pathways, yielding the equilibrium structure at room temperature and an alternative metastable one at higher temperature. Our findings address the key challenge in the synthesis of nanoalloys for technological applications, i.e., rationally exploiting the competition between kinetics and thermodynamics by designing a treatment history that forces the system into desirable metastable states.

Highly Efficient Porous Carbon Electrocatalyst with Controllable N-Species Content for Selective CO2 Reduction

We report a straightforward strategy to design efficient N doped porous carbon (NPC) electrocatalyst that has a high concentration of easily accessible active sites for the CO₂ reduction reaction (CO₂ RR). The NPC with large amounts of active N (pyridinic and graphitic N) and highly porous structure is prepared by using an oxygen-rich metal-organic framework (Zn-MOF-74) precursor. The amount of active N species can be tuned by optimizing the calcination temperature and time. Owing to the large pore sizes, the active sites are well exposed to electrolyte for CO₂ RR. The NPC exhibits superior CO₂ RR activity with a small onset potential of -0.35 V and a high faradaic efficiency (FE) of 98.4 % towards CO at -0.55 V vs. RHE, one of the highest values among NPC-based CO₂ RR electrocatalysts. This work advances an effective and facile way towards highly active and cost-effective alternatives to noble-metal CO₂ RR electrocatalysts for practical applications.

Revealing the Cluster-Cloud and Its Role in Nanocrystallization

Elucidating the early stages of crystallization from supersaturated solutions is of critical importance, but remains a great challenge. An in situ liquid cell transmission electron microscopy study reveals an intermediate state of condensed atomic clusters during Pd and Au crystallizations, which is named a "cluster-cloud." It is found that nucleation is initiated by the collapse of a cluster-cloud, first forming a nanoparticle. The subsequent particle maturation proceeds via multiple out-and-in relaxations of the cluster-cloud to improve crystallinity: from a poorly crystallized phase, the particle evolves into a well-defined single-crystal phase. Both experimental investigations and atomistic simulations suggest that the cluster-cloud-mediated nanocrystallization involves an order-disorder phase separation and reconstruction, which is energetically favored compared to local rearrangements within the particle. This finding grants new insights into nanocrystallization mechanisms, and provides useful information for the improvement of synthesis pathways of nanocrystals.