Vapor deposition has been used to create glassy materials with extraordinary thermodynamic and kinetic stability and high density. For glasses prepared from indomethacin or 1,3-bis-(1-naphthyl)-5-(2-naphthyl)benzene, stability is optimized when deposition occurs on substrates at a temperature of 50 K below the conventional glass transition temperature. We attribute the substantial improvement in thermodynamic and kinetic properties to enhanced mobility within a few nanometers of the glass surface during deposition. This technique provides an efficient means of producing glassy materials that are low on the energy landscape and could affect technologies such as amorphous pharmaceuticals.

Physical vapor deposition was employed to prepare amorphous samples of indomethacin and 1,3,5-(tris)naphthylbenzene. By depositing onto substrates held somewhat below the glass transition temperature and varying the deposition rate from 15 to 0.2 nm/s, glasses with low enthalpies and exceptional kinetic stability were prepared. Glasses with fictive temperatures that are as much as 40 K lower than those prepared by cooling the liquid can be made by vapor deposition. As compared to an ordinary glass, the most stable vapor-deposited samples moved about 40% toward the bottom of the potential energy landscape for amorphous materials. These results support the hypothesis that enhanced surface mobility allows stable glass formation by vapor deposition. A comparison of the enthalpy content of vapor-deposited glasses with aged glasses was used to evaluate the difference between bulk and surface dynamics for indomethacin; the dynamics in the top few nanometers of the glass are about 7 orders of magnitude faster than those in the bulk at Tg - 20 K.

Physical vapor deposition of indomethacin (IMC) was used to prepare glasses with unusual thermodynamic and kinetic stability. By varying the substrate temperature during the deposition from 190 K to the glass transition temperature (Tg=315 K), it was determined that depositions near 0.85Tg (265 K) resulted in the most stable IMC glasses regardless of substrate. Differential scanning calorimetry of samples deposited at 265 K indicated that the enthalpy was 8 J/g less than the ordinary glass prepared by cooling the liquid, corresponding to a 20 K reduction in the fictive temperature. Deposition at 265 K also resulted in the greatest kinetic stability, as indicated by the highest onset temperature. The most stable vapor-deposited IMC glasses had thermodynamic stabilities equivalent to ordinary glasses aged at 295 K for 7 months. We attribute the creation of stable IMC glasses via vapor deposition to enhanced surface mobility. At substrate temperatures near 0.6Tg, this mobility is diminished or absent, resulting in low stability, vapor-deposited glasses.