Supersaturation-Pathway-Controlled Gypsum Crystallization and Morphology: Nucleation- vs. Growth-Dominated Regimes with a Polycarboxylate Superplasticizer

Gypsum (CaSO4·2H2O) crystallization is highly sensitive to the supersaturation pathway, which governs the balance between nucleation and crystal growth and ultimately controls growth morphology. In this study, gypsum was synthesized via two contrasting routes—diffusion-controlled crystallization and rapid precipitation—using identical reactant systems to enable a direct comparison of distinct kinetic regimes. A polycarboxylate-based superplasticizer was incorporated to investigate pathway-dependent additive effects. Time-resolved observations reveal that rapid precipitation is characterized by high nucleation density under steep supersaturation, whereas diffusion-controlled crystallization proceeds under gradually increasing supersaturation with restricted nucleation and sustained anisotropic growth. Powder X-ray diffraction confirms the formation of phase-pure gypsum under all conditions. Scanning electron microscopy shows that the presence of the superplasticizer reduces crystal number density and modifies crystal habit in both pathways, although the extent and manifestation of these effects depend strongly on the governing kinetic regime. Under diffusion-controlled conditions, the increasing superplasticizer dosage promotes the transition from elongated to more tabular morphologies, while rapid precipitation results in dense, intergrown aggregates under high supersaturation. Overall, the results demonstrate that the effectiveness of the superplasticizer is not intrinsic but depends on the crystallization pathway. These findings provide new insight into how supersaturation profiles mediate the interplay between additive interactions and growth processes, enabling improved control over gypsum crystal morphology.