Co-O-Al Interfacial Bonding in Sol–Gel-Derived Co3O4-Coated Ceramic Membranes: Correlative FIB-HRTEM and First-Principles Analysis

Co-based oxides are commonly introduced into porous ceramic membranes to add catalytic activity, but their attachment at the atomic scale remains unclear. We examined a buried Co3O4/Al2O3 interface formed by sol–gel deposition and thermal conversion. Site-specific focused-ion-beam (FIB) lift-out, scanning transmission electron microscopy with energy-dispersive X-ray spectroscopy (STEM-EDS), and high-resolution transmission electron microscopy (HRTEM) were used to access and characterize the interface. A Co-rich spinel-type domain with a (111) lattice spacing was observed next to Al2O3(012). The observations guided density functional theory (DFT) initial models. After structural relaxation, substrate-O-mediated Co-O contacts emerged from both starting geometries: the O-bridged-start model exhibited eight contacts across four Co sites, whereas the non-bridged-start model developed three contacts around one Co site. Around the Co-O-Al linkages, there is a clear manifertation of the interface polarization and charge redistribution, indicated by charge-density-difference and Bader analyses. In both models, projected density of states (PDOS) showed coupling between Co 3d and O 2p states, while integrated crystal orbital Hamilton population (ICOHP) analysis further indicated that O atoms retained Al-O bonds while forming occupied-state Co-O bonds. These results support a representative, laterally distributed Co-O-Al motif as an atomic-scale pathway for chemically attaching the functional oxide to porous alumina.