Na-β″-alumina
ceramics are archetypical ion conductors with excellent sodium-ion
conductivity. Their processing is, however, challenging and results
in large variations in reported conductivity measurements. We systematically
reexamine the impact of sintering conditions on microstructure and
sodium-ion conductivity of Na-β″-alumina ceramics. Depending
on sintering temperature and sintering time, we measure conductivities
between 0.04 and 0.37 S/cm at 300 °C on ceramics prepared from
identical starting powders. During sintering, formation of a liquid
phase is observed above 1500 °C, which promotes densification
but leads to abnormal grain growth for extended sintering times. While
such conditions result in the highest conductivities measured for
our sample series (0.37 S/cm at 300 °C), the corresponding microstructures
are mechanically fragile. For mechanically robust, densely sintered
samples, we identify the average grain size as the dominating factor
controlling ion conductivity. For average grain sizes between 1 and
6 μm, we obtain conductivities between 0.17 and 0.27 S/cm at
300 °C. The influence of porosity in undersintered, highly porous
samples is well accounted for by Archie’s law and results in
low ion conductivities down to 0.04 S/cm at 68% density. Our insights
into microstructural factors controlling ionic conductivity such as
grain size and density are instrumental for the successful integration
of Na-β″-alumina ceramic electrolytes into next-generation
batteries.