Being heated in air at about 300 °C gibbsite γ-Al(OH)
3 is commonly known to decompose into boehmite γ-AlOOH, which eliminates water at about 500-550 °C with the formation of γ-Al
2O
3. The latter undergoes a sequence of transformations to δ- and θ-alumina modifications and finally forms α-Al
2O
3 above 1050 °C [
39,
40]. In this way, the transitional phases perform face-centered cubic packing of oxygen ions. Another way from γ-Al(OH)
3 to α-Al
2O
3 in an air atmosphere includes the formation of χ- and κ-alumina phases with hexagonal close-packed oxygen ions above 300 °C [
39]. In a water medium (below as well as above the critical point of 374 °C, 22.1 MPa), the route from gibbsite to α-Al
2O
3 was reported to pass only through the formation of boehmite, which transforms directly into α-alumina [
32,
41,
42]. In the current work, the heating of γ-Al(OH)
3 powder occurred in a presence of supercritical water as the applied mechanical pressure (> 90 MPa) and the temperature of isothermal dwell (> 380 °C) exceeded the critical parameters. Under these conditions, the formation of three new phases was observed, i.e. γ-AlOOH, χ- and α-Al
2O
3. All these phases were detected in the ceramics processed at 450 °C and 90 MPa. Worth noting that the starting gibbsite placed inside the mold for the CSP, experienced a heating with a relatively high rate. Earlier, Ingram-Jones et al. [
43] [
https://doi.org/10.1039/JM9960600073] reported that fast heating of fine γ-Al(OH)
3 (0.5 μm) powder mostly resulted in a sequence of phase transitions, first of which was its transformation to χ-Al
2O
3, while the coarse gibbsite particles (14 μm) prone to form boehmite as well as χ-Al
2O
3 at the initial step of their thermal decomposition. Gibbsite powder used in the current work could be classified as a fine-grained (
Figure A1), and the formation of χ-Al
2O
3 during its relatively fast heating appears expectable. Along with χ-Al
2O
3, γ-AlOOH is supposed to form from gibbsite at 90 MPa and then almost completely decompose into α-Al
2O
3. In the samples prepared at a higher mechanical pressure, χ-Al
2O
3 was not found. At 220 MPa and 450 °C, a single-phase α-alumina apparently formed from an intermediate boehmite phase. However, after the CSP at 350 MPa and 450 °C, α-Al
2O
3 became a minor phase in the ceramic sample mostly containing of boehmite. The mentioned observations indicated that the initial step in the CSP of gibbsite was its dehydroxylation, the route of which depended on the mechanical pressure. The rise of the applied pressure hindered the elimination of OH-groups from the solid because of the related increase in the supercritical water density inside of the mold. Almost regardless of the temperature, α-Al
2O
3 dominated in the ceramics obtained at 220 MPa, while the samples prepared at 350 MPa contained boehmite as the major phase. Similar effect of the supercritical water density on the dehydroxylation processes in γ-AlOOH as well as in BaTiO
3 were reviewed by Hayashi et al. [
44].
Phase transformation of boehmite into α-alumina in a water medium under supercritical conditions has been extensively studied previously [
32,
42,
45]. The observed evolution of the powders’ morphology derived two separate viewpoints on the alumina formation and growth. On one hand, Suchanek [
42] found no evident orientation of boehmite particles on the surfaces of alumina crystals to prove the solid-state nature of the alumina nucleation and growth and supposed dissolution-precipitation or surface diffusion processes to govern the reaction. Plyasunov [
46] reported that the dissolved form of alumina in the supercritical water is Al(OH)
3·H
2O. On another hand, Ivakin et al. [
32] revealed homogenous nucleation of α-Al
2O
3 in boehmite particles. Currently obtained ceramic samples contained phases different from Al(OH)
3, the presence of which might point to the dissolution-precipitation mechanism. However, the microstructure observed in the samples obtained at 380 °C and 350 MPa (
Figure 6a) resembled that demonstrated by Yamaguchi et al. [
7] for porous boehmite material CSPed from γ-Al(OH)
3 at milder conditions (250 °C, 270 MPa). The authors assumed that the large pores in the material were relics of the completely dissolved gibbsite particles, while the boehmite grains nucleated and grew from the solution separating them. Important to note that the pore space in boehmite could result from an intensive elimination of water during the gibbsite decomposition.
A study of the microstructural changes during the CSP at different temperatures and pressure values shows that dehydroxylation of the initial gibbsite on heating first results in the development of a fine-grained boehmite structure (
Figure 7a). Further processing leads to a coalescence of these submicron grains and a formation of larger plate-like grains of boehmite (
Figure 7b). Several authors [
12,
30] reported that at this stage of CSP, an interaction of the solid with the water medium leads to a dissociative adsorption of H
2O as well as to condensation of H
+ and OH
- with a formation of bridging oxygen between the metal ions. These processes have a decisive role in the oxygen ions diffusion, which facilitates and the mass transport between the grains and lowers the activation energy for the phase transitions. The boehmite grains of both rounded and plate-like morphologies under the CSP conditions tend to perform coalescence and finally transform homogenously into α-alumina modification (
Figure 7c). Earlier, the coalescence of the particles was also demonstrated for the CSP of ZnO [
47], CaCO
3 [
3], and Na
2Mo
2O
7 [
48].
Regardless of the phase composition, the obtained ceramics possessed a relative density in a range of 58-65 %, which is close to the density of the conventionally pressed compacts. It is likely that the porosity of the samples containing boehmite was supported by water elimination accompanying the ongoing transformation into alumina. The shape of the formed α-Al
2O
3 grains appeared similar to that observed in its crystals synthesized from the boehmite powder in a medium of supercritical water [
32,
42]. Compared to the parent boehmite grains, the grains of α-alumina increased in the size and approached to their Wulffs shape [
49], which indicates the fall of the driving force for the sintering and corresponds to the remaining porosity.