Evolution of phase composition and microstructure of sodium potassium niobate –based ceramic during pressure-less spark plasma sintering and post-annealing

This study was designed to better understand the microstructural and phase evolution of lead-free sodium potassium niobate based piezoceramics with a nominal composition (K0.5Na0.5)0.99Sr0.005NbO3 (KNNSr) during pressure-less spark plasma sintering followed by post-annealing in oxygen. The as-sintered samples were dark-coloured and electrically conductive as a result of partial reduction of Nb5+ to Nb4+ and formation of oxygen vacancies confirmed by X-ray photoelectron and Raman spectroscopy. The Rietveld refinement analysis showed that the as-sintered samples contained two perovskite phases with monoclinic Pm unit cell and slightly different unit-cell parameters. The microstructure with sub-micrometre-sized grains unambiguously confirmed that rapid heating and short dwell time hindered the grain growth. We found that post-annealing the samples at 950 °C in oxygen led to improvement in functional properties. The samples became white-coloured, the both perovskite unit cells decreased as a result of re-oxidation, while the microstructure remained essentially unchanged. The KNNSr sintered at nominal sintering temperature of 1300 °C for 3 min and post-annealed possessed a relative density of 88% and dielectric and piezoelectric properties similar to those of the conventionally sintered samples. Our findings contribute to the understanding of pressure-less spark plasma sintering of sodium potassium niobate-based materials and suggest that arrested grain growth and minimisation of alkali evaporation not necessarily lead to dense ceramic.