Engineering Faceted Nanoporosity by Reactions in Thin-Film Oxide Multilayers in Crystallographically Layered Calcium Cobaltate for Thermoelectrics

Introducing porosity is attractive for tailoring electronic, thermal, and mechanical properties of inorganic materials. Nanoporosity is typically either inherent in crystallographic channels in the structure or obtained by external templating during synthesis and sintering. However, controllably engineering porosity in materials with laminated crystal structures without channels remains a challenge. Here, we demonstrate the realization of faceted and oriented nanopores in textured Ca3Co4O9-a laminated ceramic with a misfit-layered structure of importance for thermoelectric applications-from chemical reactions in CaO/Co3O4 multilayers. We show that CaO conversion to Ca(OH)(2) and the cobalt oxide stoichiometry are key determinants of nanoporosity. Adjusting the unreacted CaO fraction alters the nanopore size and fraction and the thermoelectric properties of Ca3Co4O9. The preferred orientation of Ca3Co4O9 is underpinned by the texture of the reactant multilayers and reactant-product crystallographic relationships and density difference. Oriented pore formation is attributed to basal plane removal driven by local densification of textured Ca3Co4O9 nuclei through growth and impingement. These findings point to possibilities for controllably engineering nanoporosity and properties in a variety of inorganic materials with laminated crystal structures.