Yu Zhao*a,
Bo Chena,
Andrew Minerb and
Shashank Priya*a
aBio-Inspired Materials and Devices Laboratory (BMDL), Center for Energy Harvesting Materials and Systems (CEHMS), Virginia Tech, Blacksburg, VA 24061, USA. E-mail: spriya@vt.edu; zhaoyu@vt.edu; Fax: +1 540 231 2903; Tel: +1 540 231 0745 Tel: +1 540 553 4717
bRomny Scientific Inc., San Bruno, CA 94066, USA
First published on 7th April 2014
Bulk Al-doped zinc oxide (ZnO) with a novel self-assembled layered and correlated grain structure is found to exhibit sharp reduction in thermal conductivity. The microstructure consists of a two-dimensional layered network of oriented grains, which interconnect in the third dimension through inter-planar contacts, and grains are embedded with nano-precipitates. The contact represents anisotropic connectivity of voids trapped between the grain layers. The effects of the synthesis atmosphere and Al doping concentration upon the formation of porous correlated grains are explained by taking into account the contributions of the vapor transport mechanism for grain growth under vacuum. The inhomogeneous density distribution with spring-back effect due to the uniaxial compaction leads to the anisotropic grain growth. Compared with traditional dense ZnO, Al-doped ZnO with layered microstructure exhibits a 52% decrease in the thermal conductivity across layers (3.0 W m−1 K−1 at 573 K) while maintaining the magnitude of electrical conductivity (1000 S cm−1). The resultant power factor 4.78 × 10−4 W m−1 K−2 at 423 K and figure of merit of 0.14 × 10−3 K−1 at 572 K is higher in comparison to the normal grain structured material.
Significant improvement in reducing the thermal conductivity of thermoelectric alloys has been achieved by synthesizing nanostructured materials.1,2 When the scale of microstructural features becomes closer to the phonon mean free path then phonon scattering can be enhanced leading to a sizeable reduction in κlattice. The center for phonon scattering can be point defects (especially for heavy elements), grain boundaries, nano-scale inclusions and pores/voids.2 A recent study has indicated that phonons with long mean free path could be scattered by developing mesoscale architectures.5 Both nano- and micro-scale inclusions coupled with grain boundaries have been used for promoting the phonon scattering in bulk ZnO.6 Nano-inclusions have been found to have the pronounced effect towards reducing the thermal conductivity.6,7 Another method proposed in literature is based on the combustible nano-sized polymer particles as a void forming agent (VFA). Nano-sized voids introduced in the ZnO matrix by using combustible nanoparticles have been found to reduce the thermal conductivity by 16–25%;8 however, those samples displayed severe deterioration of electrical property. Similar degradation of electrical conductivity by void forming had been noticed in SiGe and Si systems as well.9,10 A porous networked structure provides the option for lowering κ if degradation of the electrical conductivity can be avoided.
In this study, we provide the thermoelectric characteristics of ZnO ceramics with self-assembly layered and correlated grains. The matrix was embedded with nanoscale precipitates. The interspace (long pores) between the layered grain network exhibited ordered orientation in 2D cross-section. This microstructure was found to reduce the thermal conductivity by 52% as compared to that of conventional ZnO with nano-precipitates. Unlike the porous ZnO synthesized by utilizing forming agent, SiGe, and Si, the ZnO in this work did not exhibit electrical deterioration. A characterization was conducted to investigate the thermoelectric performance of ZnO and to identify the parameters controlling the formation of microstructure with layered and correlated grain structure.
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Fig. 1 SEM micrographs of ZnO nanoparticles synthesized by sol–gel process (a) ZnO–1%Al, (b) ZnO–2%Al, (c) ZnO–3%Al; and (d) XRD patterns of synthesized ZnO–x%Al (x = 0, 1, 2, 3) nanoparticles. |
Bulk ZnO samples (1200 °C 5 hours, under 10−5 Torr condition) exhibit varying porous structures consisting of 5–10 μm grains interspersed by nano-precipitates, as shown in Fig. 2a–c. The Al concentration coupled with vacuum condition is essential ingredient in the formation of the microstructure. The grains of ZnO–1%Al (Fig. 2a) exhibit random orientation but it has higher density in comparison to the samples with higher Al doping. The ZnO–2%Al ceramic shows a self-assembled correlated grain structure arranged in layers (Fig. 2b). The ZnO–3%Al ceramic also exhibits the layered and correlated grain structure with large amount of nano-precipitates on grain surface. Due to the oriented grain growth in 2% and 3% Al-doped samples, the cross-sectional long interspaces are found to distribute themselves parallel to the sample surface. The samples synthesized under the high vacuum condition (10−5 Torr) exhibit slight better-organized correlated grain structure (inter-connection of grains in 2D and inter-connection of layers in 3D) than that under relative low vacuum condition, such as 10−2 Torr shown in Fig. S2.† XRD results (Fig. 2d) for bulk ZnO–x%Al (x = 1, 2, 3) indicate the formation of a hexagonal wurtzite type ZnO phase and a small fraction of the gahnite phase ZnAl2O4, referred as second phase precipitates.7,11,12 As seen in zoomed-in XRD spectrum in Fig. 2d, when the Al doping increases so does the intensity of XRD peaks from the gahnite phase. This change indicates that with the increase of Al doping amount more ZnAl2O4 precipitates have formed due to the reaction of ZnO and Al, which is consistent with the SEM images. EDS analysis for ZnO–3%Al (10−5 Torr) confirms that the Al concentration in precipitates is higher than that in the ZnO grain (Fig. 2e).
The average porosity values of ZnO–2%Al after sintering under vacuum 10−5 Torr and air at varying temperatures are displayed in Fig. 4a. With higher synthesis temperature, the samples sintered in vacuum show lower porosity first and the porosity remains around 25% above 1000 °C sintering temperature. The samples sintered in air show continuous densification with increase in sintering temperature. Fig. 4b shows that the grain size of both groups exhibits increasing trend with higher sintering temperature but the one in vacuum condition displays larger grain size expansion. According to the inset of Fig. 4b, the pore sizes of samples in air slightly increase and the shrinkage occurs above 1000 °C. The pore size of samples synthesized in vacuum, however, exhibited growth together with grain size. One of the mechanisms of grain growth at a relatively high temperature has been attributed to physical sintering which is controlled by the vaporization rate of ZnO.13 Above 900 °C, ZnO particles was observed on the inside surface of quartz tube by EDS (Fig. S3 and Table S1†), indicating that zinc oxide gas filled the tube during sintering. The vacuum condition in a sealed tube together with large nanoparticle surface area enhances the sublimation of ZnO whereby vapor transport plays a dominating role during the sintering. Increasing the sintering temperature enhances the vapor transport, which simultaneously reduces the driving force for densification due to its coarsening effect.14 Therefore, coarsening by the vapor transport mechanism increases the grain size accompanied by the pore growth as well, leading to the correlated grain structure with relatively high porosity. Interior of the layer with cluster of grains, another mechanism referred to as curvature-driven boundary migration,14 induces the densification in each layer at temperatures of 1100 °C. Curvature-driven boundary migration also promotes the motion of pores trapped between the layers.
The peak intensity of second phase ZnAl2O4 increases with synthesis temperature based on the XRD results (Fig. S4†). ZnO vaporization results in Al enrichment on the surface increasing the formation of ZnAl2O4 second phase. Further, the second phase formed at higher temperature (1000 °C) in comparison to the samples synthesized in vacuum, which indicates that the vacuum condition helps in the formation of ZnAl2O4. We believe that the precipitates rich on the surface prevent grains belonging to upper and lower layers from forming boundaries and favour growth of interspace between layers as shown in Fig. S4c.† This explains why when the Al concentration is relatively low (1 at%), the ZnO develops microstructure close to a normal polycrystalline (Fig. 2a). Thus, the vacuum condition coupled with Al concentration leads to the formation of the correlated grain structure.
The remaining important question is why the network of grains tends to grow horizontally to develop layered structure. The second phase precipitates or pores considered in many of the prior studies have symmetric structure as the shape evolution is driven by minimization of the interface energy. The asymmetric precipitate structures have been found in Sb2Te3–PbTe system, and energetics analysis indicated that lamellar, ribbon-like, and needle-like precipitates are residual of the interfacial energy minimization criterion.23 The layered and correlated grain structure in ZnO formation follows the energy minimization criterion as well. In our work, there is no texturing and no obvious anisotropic crystal growth, by the XRD in Fig. 2d. The horizontal direction of grain growth is probably due to the external driving forces. Thick pellets (15 mm diameter, 8 mm thickness) were pressed, diced into cubical shape, and placed in a quartz tube with different direction as shown in the schematic of Fig. 5a. According to the SEM images shown in Fig. 5a, the grain layer orientation correlates with the direction of the applied pressure during uniaxial pressing. The function of the residual stress during and after unloading might be the reason for a layered network. Different pressing pressures were applied to see the effect on the microstructure (Fig. 5b–e). Using low pressure (<10 MPa), grain growth is not confined in a specific direction clearly. Under higher pressures (100–300 MPa), the correlated grains exhibit layered structure formation. At higher pressures, the powder compact displays a stronger spring-back effect15 during unloading. Since the spring-back is much greater in the axial direction than in the radial direction,16 powder density in the radial direction is larger than that in the axial direction. On the other hand, the stress in the axial (pressing) direction is much larger than that in the radial direction. So due to Le Chatelier principle,17 the ZnO sublimation in axial direction is stronger. Therefore grain boundary tends to form and develop perpendicular to that of the press direction.
In short, vapor transport occurring through ZnO sublimation and increased Al solubility resulting through the depleted Zn concentration on particle surface, coupled with the external factors of vacuum sintering condition and uniaxial pressing, cause the formation of the layered and correlated grain structure.
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Fig. 6 Temperature dependence of (a) thermal conductivity, (b) lattice thermal conductivity, and (c) electrical conductivity for ZnO–2%Al with layered and correlated grains. The contrast sample is the identically compacted and dense ZnO–2%Al sintered under air (insert image is from contrast sample6). |
For conventional ZnO ceramics, more than 90% of the thermal conductivity is associated with lattice thermal conductivity (κlattice) where contributions arise from phonon transport and the rest is related to the electron motion. The κlattice is shown in Fig. 6b, by subtracting κelectron (calculated by Wiedemann–Franz law) from total κ. For ZnO–2%Al (10−5 Torr), the electronic thermal conductivity (κelectron) is calculated to be 0.86 to 1.14 W m−1 K−1 in the temperature range of 323–573 K. The phonon transport impediment in layered correlated grains with greatly reduces the proportion of κlattice in κ. The plot of the lattice thermal conductivity vs. 1/T shows linear relation, indicating that Umklapp processes dominate in the phonon scattering.18 Because of the low electrical conductivity and near zero electronic thermal conductivity for the contrast ZnO–2%Al sample, its thermal conductivity value can be assumed to be equal to the lattice thermal conductivity value. Thereby, κlattice of ZnO–2%Al with a layered correlated grain structure are 58% and 32% lower that of the contrast ZnO–2%Al sample at 323 K and 573 K. Since both samples in this study and the contrast sample contain nano-precipitates, we attribute the reduction in κ mainly to the layered and correlated grain microstructure.
Fig. 6c shows that ZnO–2%Al with correlated grain structure has electrical conductivity (σ) of 103 S cm−1 similar to that of thermoelectric alloys, which is greatly enhanced when compared to the ZnO–2%Al ceramics sintered in air. Sintering under vacuum condition creates large amount of intrinsic defects, which enhance the electron concentration. The samples sintered under different vacuum conditions exhibit similar magnitude of electrical conductivities with a slightly reducing trend with increasing vacuum level. The electrical resistivity of compared ZnO–2%Al is as high as 105 Ω cm, due to the formation of ZnAl2O4 and Zn vacancy in the present of oxygen.24,25 The Zn2+ vacancies compensate for the free electrons in ZnO.
The reduction of thermal conductivity for the Al-doped ZnO is ascribed to the correlated grain structure characterized by the presence of 2D network of grains forming layers. Due to the extremely low thermal conductivity of air (0.057 W m−1 K−1), interspacing between grain layers can act as a good thermal insulator. For solids with pores having dimensions exceeding the phonon mean free path of ZnO (about 30 nm), the effective thermal conductivity can be expressed as κ = κ0Φ(p), where κ0 is the thermal conductivity of the corresponding dense material, Φ is the factor determined by the porosity p. Several estimations and models for Φ have been proposed in literatures,19–21 and the shape and orientation distribution of voids influences Φ resulting in anisotropic thermal transport properties.20 The two dimensional models of pore structures are displayed in Fig. 7, and the correlated-grain structure can be simply represented by the schematic model of Fig. 7c. The long interspacing between the grain layers in ZnO is approximated by an ellipsoidal shaped void. According to an estimation performed by Braginsky21 by taking the aspect ratio of the ellipsoidal pore as 1:
4, the factor of porosity Φ was found to be 1 − (1 + J)p, when there is no thermal transportation in pores. The magnitude of J equals 0.5 for thermal conductivity of pore structure shown in case (a) and (b) and 0.1 and 0.8 along the x-axis, y-axis in case (c) respectively. The effective thermal conductivity exhibits the largest reduction along the y-axis in structure shown in Fig. 7c, for which porosity factor Φ was calculated to be ∼0.45 with 30% porosity, based on the Braginsky's model.21 This magnitude is in good agreement with the experimental value for the ZnO with layered and correlated grains, with 58% reduction of κlattice. Thus, by controlling the interconnection between the grain layers, one can modulate the morphology of the void and thus optimize the magnitude of thermal conductivity.
ZnO–2%Al synthesized under 10−5 Torr exhibited the lowest magnitude of thermal conductivity. For this sample, the Seebeck coefficient (α) was measured to be −58 to −72 μV K−1 in the temperature range of 323 to 572 K (Fig. 8a). This results in the room-temperature Power Factor (P. F.) as high as 3.67 × 10−4 W m−1 K−2, which is about 20 times larger than that of Al-doped ZnO nanocomposites reported recently.7 With increasing measurement temperature, the power factor increases to 4.78 × 10−4 W m−1 K−2 at 423 K and then slightly decreases to 4.16 × 10−4 W m−1 K−2 at 572 K due to the faster σ decrease than α increase. We expect that the power factor could rise again at higher temperature because of the square dependence of α in P. F. and the increasing trend of α reported in literature.3,7,11 The figure of merit (Z) of ZnO–2%Al (10−5 Torr) is shown in Fig. 8b as a function of temperature. The room temperature Z value 0.07 × 10−3 K−1 is about 3 times larger than that reported by Tsubota.22 The Z value continuous increases with temperature and reaches 0.14 × 10−3 K−1 at 572 K, which is also larger than the results reported in the literature.22
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Fig. 8 Temperature dependence of (a) Seebeck coefficient and calculated power factor (b) figure of merit Z for ZnO–2%Al sample synthesized under 10−5 Torr. |
Footnote |
† Electronic supplementary information (ESI) available. See DOI: 10.1039/c4ra01220h |
This journal is © The Royal Society of Chemistry 2014 |