1 Naica Cave, Mexico 5 My, 50 C CaSO4·2H2O 1.2 × 15 m 2 High temperature methods Czochralski Stockbarger and Bridgman Verneuil Zone melting Medium temperature methods Fluxes, Ionic Liquids Electrochemical from melts Hydrothermal Vapor phase transfer Sublimation Low temperature methods Solution Gel Growth of Single Crystals 3 Many different crystal growing techniques exist, hence one must think very carefully as to which method is the most appropriate for the material under consideration, size of crystal desired, stability in air, morphology or crystal habit required Growth of Single Crystals Crystallization techniques: vapor, liquid, solid phase Single crystals vital for meaningful property measurements of materials allow measurement of anisotropic phenomena (electrical, optical, magnetic, mechanical, thermal) in anisotropic crystals (symmetry lower than cubic)  fabrication of devices Y3Al5O12 (YAG = yttrium aluminum garnet) and beta-beryllium borate (BBO) for doubling and tripling the frequency of CW or pulsed laser light SiO2 (quartz) crystal oscillators for mass monitors lithium niobate for photorefractive applications 4 Thermodynamics and Kinetics of Crystallization As a material cools off the average kinetic energy drops Boltzman Distribution T1 > T2 5 Stages of Crystallization • Nucleation – formation of nuclei of critical size • Growth – diffusion of material toward the critical nuclei, depositon vs. dissolution, crystal growth 6 Formation of Nuclei Molecules are always bumping into each other – sometimes they stick At lower kinetic energies more molecules stick together = form nuclei Cooling Addition of monomer 7 Transformation from Liquid to Solid VOLUME The energy of a crystalline phase is less than that of a liquid The difference = the volume free energy Gv (a negative value) As the solid grows in size, the magnitude of the total volume free energy increases The volume free energy Gv drives crystallization SURFACE When solids form in a liquid there is an interface created The surface free energy, SL = the solid/liquid interfacial energy associated with this interface (changed in different solvents) As the solid grows, the total surface free energy increases (a positive value) The surface free energy hinders crystallization 8 Transformation from Liquid to Solid 9 Thermodynamics of Nucleation The driving force = the supersaturated solution is not stable in energy. The total change in free energy for the nucleating system is the sum of the two factors. For spherical nuclei GT = 4/3 r 3 Gv + r 2 SL The volume free energy goes up with the cube of the radius The surface free energy goes up with the square of the radius GT has a maximum at a critical radius – critical free energy GN If just a few molecules stick together, they will redissolve If enough molecules stick together, the embryo will grow 10 Volume Free Energy m V V SRT G ln  ΔGV – the free energy change between the ‘monomer’ in solution and in a unit volume of bulk crystal S – supersaturation = the quotient of the actual concentration [M] and the concentration of the respective species at equilibrium with the flat crystal surface [M], indicates how far away from equilibrium the system is: Vm – molar volume of the monomer composing the bulk crystal      M M S 11 r: radius of spherical nuclei r*: critical radius (r>r* seed grows by itself) GT: total free energy change Gs: surface free energy change Gv: volume free energy change GN: critical free energy change (activation energy to nucleation) GT = 4r2SL + 4/3r3GV Nucleation G GN 12 Total Free Energy of a Solid-Liquid System Surface Energy Volume Energy Critical Radius rc 4/3 r 3Gv r2 SL G   2 3 4 3 ln4 r V SRTr G m T  13 Supersaturated Solutions If the liquid is just at the freezing point, only a few molecules stick, because they have comparatively high energy. As the liquid is cooled, more molecules can form into nuclei. When the nucleus is big enough (because of undercooling) the supercooled liquid suddenly changes to a solid. 14 Nucleation - Critical Radius rc rc critical nuclei radius is: S = supersaturation SRT V G r mSL V SL c ln 22     At larger supersaturation, the critical radius of nuclei is smaller   2 3 4 3 ln4 r V SRTr G m T  0 )(   dr Gd T 15 Nucleation - Critical Free Energy GN  2 23 ln3 16 SRT V G mSL N   The free energy necessary to form stable nuclei Thermodynamic barrier to nucleation 16 Rate of Nucleation ΔGN – the free energy barrier to nucleation S – supersaturation Vm – molar volume of the bulk crystal Arrhenius equation                   2233 23 ln3 16 expexp SNTk V A kT G A dt Nd A mSLN  Nucleation Rate 17 Vm = 3.29 × 10−5 m3 mol−1 (the value for CdSe)                   2233 23 ln3 16 expexp SNTk V A kT G A dt Nd A mSLN  18 Homogeneous Nucleation The process of solid formation from liquid phase = homogeneous nucleation It only occurs if the material is very pure The size of the critical radius is: Metal crystallization from melts T is the undercooling Metals often experience undercooling of 50 to 500 ºC TH T r f mSL   2* SRT V G r mSL V SL c ln 22     19 Heterogeneous Nucleation Homogeneous nucleation usually only occurs under very clean conditions Impurities provide a “seed” for nucleation Solidification can start on a wall It’s like cloud seeding, or water condensing on the side of a glass Adding impurities on purpose = inoculation GN hetero =  GN homo Growth 20 Growth = monomer diffusion + surface reaction the growth rate of spherical particles (dr/dt) depends on: - the flux of the monomers to the particles (J) - the rate of surface reaction (k) 21 Growth Growth by diffusion the growth rate of spherical particles (dr/dt) dt dr V r J m 2 4  dx dC DxJ 2 4   sCC rr DJ       4      C C r r s dC J D x dx 4 2 22 La Mer Mechanism Monomer formation - concentration of monomer increases to a critical value Burst nucleation - many nuclei are generated at the same time Growth - the nuclei grow without additional nucleation, all of the particles nucleate simultaneously, their growth histories are the same Control of the size distribution of the ensemble of particles during growth synthesis of monodisperse nanocrystals 3 Separate stages: - Monomer formation - Burst nucleation - Growth by diffusion 23 Stage I - The concentration of “monomer”, (the minimum subunit of bulk crystal) constantly increases with time, precipitation does not occur even under supersaturated conditions (S > 1), the energy barrier for spontaneous homogeneous nucleation is too high. Stage II - Nucleation occurs, the degree of supersaturation is high enough to overcome the energy barrier for nucleation, the formation and accumulation of stable nuclei. The rate of monomer consumption exceeds the rate of monomer supply, the monomer concentration decreases until it reaches the level at which the nucleation rate is zero. Stage III - The growth stage, nucleation stopped, the particles keep growing as long as the solution is supersaturated by diffusion of monomer towards crystals 24 Growth and Solidification - Grain Size Solidification caused by homogeneous nucleation occurs suddenly, and only produces a few grains In heterogeneous nucleation, solidification occurs on many “seeds”, so the grains are smaller, and more uniform If a melt is cooled slowly, and the temperature is the same throughout, solidification occurs with equal probability everywhere in the melt. Metals are usually cooled from the container walls – so solidification starts on the walls 25 Nucleation vs. Crystal Growth (solution or melt) Undercooling – cooling below the melting point relations between undercooling, nucleation rate and growth rate of the nuclei large undercooling: many small nuclei (spontaneous nucleation) growth rate small small undercooling: few (evtl. small) nuclei growth rate high 26 Nucleation vs. Crystal Growth Rate of nucleation Rate of growth Ta = small undercooling, slow cooling rate Fast growth, slow nucleation = Few coarse crystals Tb = larger undercooling, rapid cooling rate Rapid nucleation, slow growth = many fine-grained crystals Tc = very rapid cooling Nearly no nucleation = glass 27 Heat of Fusion When the liquid solidifies, energy must be removed. In planar growth the energy is conducted into the solid and out through the walls of the container If the melt is not well inoculated Solidification starts on the walls The surrounding liquid is supercooled, so the solid quickly grows All heat that is evolved is hard to conduct away Some of it is absorbed by the surrounding liquid which then heats up 28 CZOCHRALSKI or KYROPOULOS METHOD Jan Czochralski (1885 – 1953) Growth of Single Crystals 1917 Crystal pulling technique Single crystal growth from the melt precursor(s) Crystal seed placed in contact with surface of melt Temperature of melt held just above melting point = highest viscosity, lowest vapor pressure Seed gradually pulled out of the melt, 1 mm per hour Melt solidifies on surface of seed Melt and seed usually rotated counterclockwise with respect to each other to maintain constant temperature and to facilitate uniformity of the melt during crystal growth, 10 rpm Produces higher quality crystals, less defects Inert atmosphere, often under pressure around growing crystal and melt to prevent any materials loss 29 CZOCHRALSKI or KYROPOULOS METHOD Growth of Single Crystals 30 Diam 300 mm Length 2 m Weight 265 kg 31 Growing bimetallic crystals like GaAs Layer of molten inert oxide like B2O3 spread on to the molten feed material to prevent preferential volatilization of the more volatile component of the bimetal critical for maintaining precise stoichiometry for example Ga1+xAs and GaAs1+x which are respectively rich in Ga and As, become p-doped and n-doped Growth of Single Crystals 32 The Czochralski crystal pulling technique for growing large single crystals in the form of a rod subsequently cut and polished for various applications Si Ge GaAs LiNbO3 SrTiO3 NdCa(NbO3)2 Growth of Single Crystals 33 Six steps in the CZ growth of a silicon single crystal: a) Evacuation and heating of the polycrystalline silicon (“pumping”) b) Setting the temperature of the Si melt just above 1414 ºC (“melting”) c) Dipping the thin Si seed crystal into the homogeneous Si melt (“dipping”) d) Initiating crystallization at the neck of the thin Si seed (“necking”) e) Adjustment of the shoulder of the desired single crystal diameter (“shoulder”; four positions which portray the fourfold drawing axis [100] are visible at the hot, light marginal zone of the single crystal) f) Growing phase of the single crystal with constant diameter (“body”). 34 STOCKBARGER AND BRIDGMAN METHODS Stockbarger method is based on a crystal growing from the melt, involves the relative displacement of melt and a temperature gradient furnace, fixed gradient and a moving melt/crystal Growth of Single Crystals 35 Bridgman method is again based on crystal growth from a melt, but now a temperature gradient furnace is gradually cooled and crystallization begins at the cooler end, fixed crystal and changing temperature gradient STOCKBARGER AND BRIDGMAN METHODS Growth of Single Crystals 36 Both methods are founded on the controlled solidification of a stoichiometric melt of the material to be crystallized Enables oriented solidification Melt passes through a temperature gradient Crystallization occurs at the cooler end Both methods benefit from seed crystals and controlled atmospheres (sealed containers) Mylar0.5-1.5-189Ar (!) Pyrex1-5434AgBr graphite6-601083Cu Ir5-101790FeAl2O4 Mo2-8 mm h-12037Al2O3 container materialvelocity of grad. mp (oC)crystal 37 Zone Melting Purification of solids Crystal growth Thermal profile furnace, RF, arc, electron beam heating Material contained in a boat (must be inert to the melt) Only a small region of the charge is melted at any one time Initially part of the melt is in contact with the seed Boat containing sample pulled at a controlled velocity through the thermal profile furnace - zone of material melted Oriented solidification of crystal occurs on the seed 38 Zone Melting Zone refining methods for purifying solids Partitioning of impurities occurs between melt and the crystal Impurities concentrate in liquid more than the solid phase, swept out of crystal by moving the liquid zone Used for purifying materials like W, Si, Ge to ppb level of impurities, often required for device applications 39 - a small slice of the sample is molten and moved continuously along the sample - impurities normally dissolve preferably in the melt (!! icebergs in salt water don‘t contain any salt !!) - segregation coefficient k: k = csolid/cliquid (c: concentration of an impurity) only impurities with k < 1 can be removed by zone melting !! Zone Melting 40 Zone Melting 41 FLOATING ZONE METHOD Molten zone is confined by surface tension between a polycrystalline ingot and a single-crystal seed Zone Melting Verneuil Fusion Flame Method 42 1902 - French chemist Auguste Verneuil the first commercially successful method of manufacturing synthetic gemstones - ruby, sapphire, diamond simulants rutile and strontium titanate Verneuil Fusion Flame Method 43 Useful for growing crystals of extremely high melting metal oxides Examples include: Ruby from Cr3+ /Al2O3 powder Sapphire from Cr2 6+ /Al2O3 powder Spinel, CoO, ferrites Starting material fine powder Passed through O2/H2 flame or plasma torch Melting of the powder occurs in the flame Molten droplets fall onto the surface of a seed or growing crystal Controlled crystal growth Lowered 10 mm/hour 44 THE FLUX METHOD Material dissolved in a suitable flux = solvent (metals, fluorides, oxides), lower melting point than the pure solute Single crystals grown from supersaturated solution Suitable for materials which:  vaporize or dissociate at temperatures above their mp  there are no suitable containers at elevated temperatures Material Flux As Ga B Pt Si, Ge Pb, Zn, Sn GaAs, GaP Pb, Zn, Sn BaTiO3 KF ZnO PbF2 ZnS SnF2 MgFe2O4 NaF Co3O4 B2O3 – PbO Fe2O3 Na2B4O7 TiO2 Na2B4O7 – B2O3 45 THE FLUX METHOD AlF3 2.0 g of AlF3, 25.0 g of PbCl2, 2.5 g PbF2 24 h at 1200 K, cooled at 4 deg h1 down to 723 K thick platelets and small cubes 46 THE SOLUTION METHOD Suitable for materials with a reasonable solubility in the selected solvent: water, organic solvents, NH3(l) , HF, SO2(l) Nucleation homogeneous heterogeneous Dilute solution, solvent with low solubility for given solute Supersaturated solution, seed crystals Single crystals grown at constant supersaturation Techniques:  slow evaporation  slow cooling  vapor diffusion  solvent diffusion  reactant diffusion  recirculation, thermal differential, convection  cocrystallants (OPPh3 for organic proton donors)  counterion, similar size of cation and anion least soluble  ionization of neutral compounds, protonation/deprotonation, hydrogen bonding Rochelle salt: d-NaKC4H4O6.4H2O (tartrate) KDP alum 47 KDP crystals (KH2PO4) grown from supersaturated solution crystal seed slow cooling a frequency converter converts the infrared light at 1053 nm into the ultraviolet at 351 nm Hydrothermal Synthesis 48 1957 - Bell Labs Water medium High temperature growth, above normal boiling point Water acts as a pressure transmitting agent Water functions as solubilizing phase Often a mineralizing agent is added to assist with the transport of reactants and crystal growth Speeds up chemical reactions between solids Crystal growth hydrothermally involves: Temperature gradient reactor = autoclave (a bomb !!) Dissolution of reactants at one end Transport with help of mineralizer to seed at the other end Crystallization at the other end Hydrothermal Synthesis 49 Useful technique for the synthesis and crystal growth of phases that are unstable in a high temperature preparation in the absence of water materials with low solubility in water below 100 o C Some materials have negative solubility coefficients, crystals can grow at the hotter end in a temperature gradient hyrdothermal reactor Example: -AlPO4 (Berlinite) important for its high piezoelectric coefficient (larger than -quartz with which it is isoelectronic) used as a high frequency oscillator Hydrothermal growth of quartz crystals Water medium, nutrients 400 o C, seed 360 o C, pressure 1.7 kbar Mineralizer 1M NaOH Uses of single crystal quartz: Radar, sonar, piezoelectric transducers, monochromators, XRD Annual global production hundreds of tons of quartz crystals Hydrothermal Synthesis 50 Hydrothermal crystal growth is also suitable for growing single crystals of: Ruby: Cr3+ /Al2O3 Corundum: -Al2O3 Sapphire: Cr2 6+ /Al2O3 Emerald: Cr3+ /Be3Al2Si6O18 Berlinite: -AlPO4 Metals: Au, Ag, Pt, Co, Ni, Tl, As Role of the mineralizer: Control of crystal growth rate: choice of mineralizer, temperature and pressure Solubility of quartz in water is important 51 HYDROTHERMAL SYNTHESIS SiO2 + 2H2O Si(OH)4 0.3 wt% even at supercritical temperatures >374 o C A mineralizer is a complexing agent (not too stable) for the reactants/precursors that need to be solublized (not too much) and transported to the growing crystal Some mineralizing reactions: NaOH mineralizer, dissolving reaction, 1.3-2.0 kbar 3SiO2 + 6OH Si3O9 6+ 3H2O Na2CO3 mineralizer, dissolving reaction, 0.7-1.3 kbar SiO2 + 2OH SiO3 2+ H2O CO3 2+ H2O  HCO3 + OHNaOH creates growth rates about 2x greater than with Na2CO3 because of different concentrations of hydroxide mineralizer 52 HYDROTHERMAL SYNTHESIS Examples of hydrothermal crystal growth and mineralizers Berlinite -AlPO4 Powdered AlPO4 cool end of reactor negative solubility coefficient!!! H3PO4/H2O mineralizer, AlPO4 seed crystal at hot end Emeralds Cr3+ /Be3Al2Si6O18 SiO2 powder at hot end 600 o C, NH4Cl or HCl/H2O mineralizer, 0.7- 1.4 kbar, cool central region for seed, 500 o C, Al2O3/BeO/Cr3+ dopant powder mixture at other hot end 600 o C 6SiO2 + Al2O3 + 3BeO  Be3Al2Si6O18 Beryl contains Si6O18 12six rings 53 HYDROTHERMAL SYNTHESIS Metal crystals Metal powder at cool end 480 o C, Mineralizer 10M HI/I2 Metal seed at hot end 500 o C. Dissolving reaction that also transports Au to the seed crystal: Au + 3/2I2 + I AuI4 Metal crystals grown this way include Au, Ag, Pt, Co, Ni, Tl, As at 480-500 o C Diamonds Ni + C + H2O diamond 800 C, 140 MPa 54 Carbon films on SiC fibers SiC + 2 H2O C + 2 H2 + SiO2 Zeolites Al(OH)3, SiO2, NaOH, template Mx/n [(AlO2)x(SiO2)y]. mH2O 100 MPa 300-600C HYDROTHERMAL SYNTHESIS 55 HYDROTHERMAL SYNTHESIS necessitates knowledge of what is going on in an autoclave under different degrees of filling and temperature Pressure, volume, temperature tables of dense fluids like water Critical point of water: 374.2 o C, 218.3 bar Density of liquid water decreases with T Density of water vapor increases with T Density of gas and liquid water the same 0.32 gcm-3 , at the critical point Liquid level in autoclave rises for > 32% volume filling Autoclave filled at 250 o C for > 32% volume filling For 32% volume filling liquid level remains unchanged and becomes fluid at critical temperature 56 HYDROTHERMAL SYNTHESIS 57 HYDROTHERMAL SYNTHESIS Tables of pressure versus temperature for different initial volume filling of autoclave must be consulted to establish a particular set of reaction conditions for a hydrothermal synthesis or crystallization Safety: if this is not done correctly, with proper protection equipment in place, you can have an autoclave explosion that can kill!!! 58 BULK-MATERIAL DISSOLUTION TECHNIQUE large zeolite crystals: up to 3 mm, SOD, MFI, ANA,CAN, JBW autoclave, PTFE liner quartz tube (SiO2) TPAOH, HF, H2O 200 C, 25-50 days ceramic tube (SiO2, Al2O3) NaOH, H2O 100-200 C, 7-20 days Small surface area, low dissolution rate, saturation concentration maintained, only a few nuclei are produced at the beginning, no large crystals formed in the stirred reactions, concentration gradients 59 DECOMPLEXATION CRYSTALLIZATION crystallization under ambient conditions, low temperature and pressure, provides kinetic products, control of crystal size and morphology, habit AgX, X = Cl, Br, I MX, M = H, Na, K, NH4 AgI + HI H+ + [AgI2]aqueous solution overlayer absolute ethanol, HI diffusion, decomplexation of AgI, hexagonal plates 5 mm AgX + 2 NH3 [Ag(NH3)2]+ + XX = Cl, Br, slow evaporation (3-5 days), AgX crystals 60 AgI + KI K+ + [AgI2] concentration gives K[AgI2] crystals  dilution by slow diffusion gives 20 mm AgI crystals  warming gives AgI crystals (inverse temperature dependence of AgI solubility in KI) CuCl + HCl H+ + [CuCl2]- CuCl HgI2 + KI [HgI3]- [HgI4]2- HgI2 PbO + hot KOH solution, slow cooling provides PbO as 2 mm yellow needles and 1 mm red blocks 61 COMPLEXATION-MEDIATED CRYSTALLIZATION Salts with high lattice energy fluorides, carbonates, acetates Solubilized in organic solvents by crown ethers Crystallization provides uncomplexed salts NaOOCCH3.3H2O dissolves in cyclohexane with 15-crown-5 prismatic crystals 62 COMPLEXATION-MEDIATED REACTION CRYSTALLIZATION Two soluble salts react to produce an insoluble phase  aqueous solutions  nonaqueous solvents CaCO3 calcite TD stable phase at room temp., in H2O vaterite kinetic product aragonite TD stable at high temperature CaCl2 (in MeOH) + NaHCO3 (in MeOH, 18-crown-6) microcrystalline calcite upon aging converts to nanocrystalline vaterite, surface stabilization by surface chelatation 63 THE GEL METHOD Large single crystals  hydrogels: silicagel (water glass), polyvinyl alcohol, gelatin, agar Silicate gel Impregnation with metal or ligand, setting the gel = condensation, crosslinking, pH control of the condensation rate Layered with the solution of ligand or metal Slow diffusion, xtal growth CuSO4 + [NH3OH]Cl Cu Pb(OAc)2 + Zn Pb + Zn(OAc)2 Pb(OAc)2 + KI PbI2 + 2 KOAc Liesegang rings, agates RbSnBr3, CsSb2I5 semiconductors 64 THE GEL METHOD  nonaqueous gels PEO (MW = 100 000) in 1,2-dichloroethane + MeOH, EtOH, PrOH, DMF, CH3CN, DMSO Impregnation with metal or ligand Layered with the solution of ligand or metal Slow diffusion, crystal growth U-tube, counter-diffusion Concentration programming, increasing concentrations Ostwald rippening = larger xtals grow, smaller dissolve 65 ELECTROCHEMICAL REDUCTIVE SYNTHESIS, CRYSTAL GROWTH Molten mixtures of precursors, product crystallizes from melt Melt electrochemistry: Electrochemical reduction CaTi(IV)O3 (perovskite)/CaCl2 (850 o C)  CaTi(III)2O4 (spinel) Na2Mo(VI)O4/Mo(VI)O3 (675 o C)  Mo(IV)O2 (large crystals) Li2B4O7/LiF/Ta(V)2O5 (950 o C)  Ta(II)B2 Na2B4O7/NaF/V(V)2O5/Fe(III)2O3 (850 o C)  Fe(II)V(III)2O4 (spinel) Na2CrO4/Na2SiF6 (T o C)  Cr3Si Na2Ge2O5/NaF/NiO  Ni2Ge 66 ELECTROCHEMICAL REDUCTIVE SYNTHESIS, CRYSTAL GROWTH Phosphates  phosphides Carbonates  carbides Borates  borides Sulfates  sulfides Silicates  silicides Germanates  germides 67 Synthesis of Amorphous Materials Quenching of molten mixture of metal oxide with a glass former (P2O5, V2O5, Bi2O3, SiO2, CaO, …), large cooling rates required (>107 K s1) Ion beam sputtering Thermal evaporation Thermal decomposition of organometallic precursors (Fe(CO)5, …) Cr2O3, MnO2, PbO2, V2O5, Fe2O3 Sonochemical decomposition of organometallic precursors (Fe(CO)5, M(acac)n,… Precipitation on metal hydroxides, transformation to hydrous oxides MW heating of metal salt solution Cr2O3, Fe2O3