The crystallographic structure and
microstructure of solid electrolytes,
such as Li7La3Zr2O12 (LLZO),
have a profound impact on their reactivity, conductivity, and stability
toward dendrites in solid-state batteries. Controlling the material’s
structure and morphology requires fine control during the synthesis
process, where multiple conditions (precursor particle size/distribution,
calcination/sintering temperature, ramp rate, etc.) influence performance.
This paper describes, for the first time, the operando characterization
of the calcination process using synchrotron X-ray diffraction combined
with a mesoscale model of grain growth during the calcination and
densification of LLZO. The model is then used to guide synthesis conditions
to enhance the densification process. The X-ray data reveal significant
coarsening of the initial nanophase lanthanum zirconate precursors
during conversion to LLZO. The mesoscale model shows that the activation
energy for diffusion during calcination is lower than that during
sintering, indicating the inherent coupling between the chemical reaction
and grain growth processes. Simulations suggest that particles with
small and bimodal size distribution experience better densification,
as does precise grading (smaller particles near the surface and larger
particles at the center) of different-sized particles. The approach
described here can be adapted to understand and guide the synthesis
of other materials that undergo calcination and sintering (e.g., transition
metal oxide cathodes).