Nanocrystallization and phase transformation in monodispersed ultrafine zirconia particles from various homogeneous precipitation methods

Monodispersed ultrafine (nano- to micrometer) zirconia precursor powders were synthesized by three different physicochemical methods: (I) forced hydrolysis, (II) homogeneous precipitation in inorganic salt solutions, and (III) hydrolysis/condensation of alkoxide. The forced hydrolysis method produced monoclinic nanocrystalline particles (cube shaped) of nanometer scale, which depended largely on the initial salt concentration. Methods II and III, both involving the use of alcohol as a solvent, exhibited a faster particle formation rate and generated amorphous ultrafine (submicrometer) monodispersed microspheres, indicating that the presence of alcohol may have stimulated particle nucleation due to its low dielectric property (and, thus, the low solubility of nucleus species in mixed water-alcohol solutions). Nucleation and growth of the particles in solutions are discussed based on the measurements obtained by small-angle X-ray scattering (SAXS) and dynamic light scattering (DLS). High-temperature X-ray diffraction (HTXRD) and TGA/DTA studies elucidated the differences in phase transformation for different types of powders. The most interesting finding was the nonconventional monoclinic nanocrystal nucleation and growth that occurred prior to transformation to the tetragonal phase (at 1200°C) during the heat treatment of the nanocrystalline powders produced by the forced hydrolysis.