Sequential pairwise reactions dictate phase evolution in the solid-state synthesis of multicomponent ceramics

Solid-state synthesis from powder precursors is the primary processing route to advanced multicomponent ceramic materials. Optimizing ceramic synthesis routes is usually a laborious, trial-and-error process, as heterogeneous mixtures of powder precursors often evolve through a complicated series of reaction intermediates. Here, we show that phase evolution from multiple precursors can be modeled as a sequence of interfacial reactions which initiate between two phases at a time. By using ab initio thermodynamics to calculate which pairwise interface is most reactive, we can understand and anticipate which non-equilibrium phases will form during solid-state synthesis. Using the classic high-temperature superconductor YBa$_2$Cu$_3$O$_{6+x}$ (YBCO) as a model system, we directly observe these sequential pairwise reactions with in situ X-ray diffraction and transmission electron microscopy. Our model rationalizes a remarkable observation--that YBCO can be synthesized in 30 minutes when starting with a BaO$_2$ precursor, as opposed to 12+ hours with the traditional BaCO$_3$ precursor.