Formation Mechanism and Properties of Foam-Structured ZnO Films Prepared Using Catalyst-Free Carbothermal Method

Foam-structured ZnO films were formed on c-axis Al2O3 substrates by using a catalyst-free carbothermal method. The morphological properties of the films strongly depended on their substrate position in the reactor, implying that the quantity of Zn vapor transported played a crucial role in determining the film structure. The formation mechanism of the films is proposed to be as follows: with increased transport of Zn vapor, vaporized Zn elements transformed into liquid Zn nanoparticles, and the liquid Zn elements on the rods promoted the new nucleation of ZnO nanorods. The repeated growth of ZnO rods at the nucleation sites led to the foam-like structure. The as-formed foam-structured ZnO films exhibited the wurtzite crystal structure, and the atomic composition ratio of Zn to O was 1 : 0.85. The main photoluminescence emissions were centered at 3.3 and 2.5 eV, and they were attributed to band-to-band and defect-related transitions, respectively.