Influence of powder characteristics on cold sintering of nano-sized ZnO with density above 99 % Khushnuda Nur a,b,c* , Tarini Prasad Mishra a , João Gustavo Pereira da Silva a , Jesus Gonzalez-Julian a , Martin Bram a,d , Olivier Guillon a,c,e a Forschungszentrum Jülich GmbH, Institute of Energy and Climate Research: Materials Synthesis and Processing (IEK-1), 52425, Jülich, Germany b Department of Metallurgical and Materials Engineering, G.T Road, UET Lahore, Lahore, Pakistan. c RWTH Aachen University, Institute of Mineral Engineering, 52064 Aachen, Germany d Ruhr-Universität Bochum, Institut für Werkstoffe, Universitätsstraße 150, 44801 Bochum, Germany e Jülich Aachen Research Alliance, JARA-Energy, 52425 Jülich, Germany. CRediT: Khushnuda Nur (Methodology, validation, investigation, writing – original draft), Tarini Prasad Mishra (Writing – Review & Editing), João Gustavo Pereira da Silva (Formal Analysis), Jesus Gonzalez- Julian (Resources, Writing – Review & Editing), Martin Bram (Supervision, Writing – Review & Editing), Olivier Guillon (Supervision, Project Administration, Funding Acquisition, Writing – Review & Editing) Abstract Cold sintering parameters such as, temperature, pressure, aqueous phase, heating rate and dwelling time has been widely discussed in the literature but the role of starting powder with respective microstructure development is mostly overlooked. There is a need for understanding the effect of powder agglomerates and the role of inter particle friction on the densification behavior during cold sintering process. Present study encompasses investigation and optimization of these parameters for ZnO which enabled > 99 % of relative density with grain sizes below 200 nm. Additionally, role of external atmosphere was also studied to investigate its impact on densification during the process. All cold sintering experiments were carried out in a FAST/SPS device for studying aqueous phase evaporation and ensuring the reproducibility of process parameters. Microstructure characterization (scanning and transmission electron microscopy) showed – without any post heat treatment– defect free grain boundary structure opposite to what documented by previous studies. Keywords: Cold Sintering; FAST/SPS; powder agglomeration; parameters' optimization; grain boundary * Corresponding author: [email protected] (Khushnuda Nur).