Nanocomposite thin films comprised
of metastable metal carbides
in a carbon matrix have a wide variety of applications ranging from
hard coatings to magnetics and energy storage and conversion. While
their deposition using nonequilibrium techniques is established, the
understanding of the dynamic evolution of such metastable nanocomposites
under thermal equilibrium conditions at elevated temperatures during
processing and during device operation remains limited. Here, we investigate
sputter-deposited nanocomposites of metastable nickel carbide (Ni3C) nanocrystals in an amorphous carbon (a-C) matrix during thermal postdeposition processing via complementary
in situ X-ray diffractometry, in situ Raman spectroscopy, and in situ
X-ray photoelectron spectroscopy. At low annealing temperatures (300
°C) we observe isothermal Ni3C decomposition into
face-centered-cubic Ni and amorphous carbon, however, without changes
to the initial finely structured nanocomposite morphology. Only for
higher temperatures (400–800 °C) Ni-catalyzed isothermal
graphitization of the amorphous carbon matrix sets in, which we link
to bulk-diffusion-mediated phase separation of the nanocomposite into
coarser Ni and graphite grains. Upon natural cooling, only minimal
precipitation of additional carbon from the Ni is observed, showing
that even for highly carbon saturated systems precipitation upon cooling
can be kinetically quenched. Our findings demonstrate that phase transformations
of the filler and morphology modifications of the nanocomposite can
be decoupled, which is advantageous from a manufacturing perspective.
Our in situ study also identifies the high carbon content of the Ni
filler crystallites at all stages of processing as the key hallmark
feature of such metal–carbon nanocomposites that governs their
entire thermal evolution. In a wider context, we also discuss our
findings with regard to the much debated potential role of metastable
Ni3C as a catalyst phase in graphene and carbon nanotube
growth.