Weakly-agglomerated nanocrystalline (ZrO2)1−x(Sc2O3)x (x = 0.02–0.16) powders with high surface area (106–186 m2 g−1) and uniform particle size (5.7–9.5 nm) were synthesized by a two-step hydrothermal process in the presence of urea, and their complex phase evolution upon calcinations over 400–1400 °C were studied by a combined utilization of X-ray diffraction, in situ high temperature X-ray diffraction, near infrared Fourier transform Raman and ultraviolet Raman spectroscopies. It was discovered that the growth of the grains comprised two stages, and the apparent activation energies, Ea1 (<800 °C) and Ea2 (>800 °C), are in the range of 5.5–12 kJ mol−1 and 80–140 kJ mol−1, respectively. The crystallite size, microstrain, surface area and growth activation energy of the samples showed a strong dependence on the Sc3+ doping concentration. The nanocrystalline (ZrO2)1−x(Sc2O3)x samples underwent complex phase transitions upon calcination from 800 to 1000 °C. Tetragonal and cubic phases have been preserved when the samples calcined below 800 °C as a result of crystallite size and doping effects. At elevated calcination temperature of 1000 °C, the compositions at x = 0.04, 0.10 and 0.14 seemed to be in the metastable phase boundaries of m + t, t + β (Sc2Zr7O17) and β + γ (Sc2Zr5O13), respectively. As calcined at 1400 °C, the grain size was in the micrometre regime, and t → m, c → t″, c → β and c → γ phase transitions occurred on the cooling stage for x ≤ 0.04, x = 0.08, 0.10 ≤ x ≤ 0.12 and x ≥ 0.14, respectively, resulting in the existence of m, t, t″, β and γ phases in turn at room temperature. Moreover, it was found that the tetragonal phase has been enriched at the surface region for the as-calcined (ZrO2)0.94(Sc2O3)0.06 and (ZrO2)0.92(Sc2O3)0.08 samples.
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