High rate synthesis of nanophase materials

In 1986, Gleiter and co-workers introduced the concept of synthesis of non-agglomerated nanoparticles by rapid condensation from the vapor phase in a reduced pressure environment. The source of the material was an evaporative source, which is ideally suited for low vapor pressure and low melting point metals. In order to broaden the scope of the materials synthesis, we have developed a variation in this process in which the source of the nanophase material is a metalorganic precursor. In this new Chemical Vapor Condensation (CVC) process, the key parameters are gas phase residence time, temperature of the hot-wall reactor, and precursor concentration in the carrier gas. The CVC processing unit is an effective nanoparticle generator which is suitable for many different types of materials. Examples are, SiC, Si3N4, Al2O3, TiO2, ZrO2 and other refractory compounds. More recently, we have extended our processing capabilities to include a flat flame combustor unit which is particularly suited to synthesis of oxide phases either as powders, films, coatings or free standing forms. We are laying the groundwork of computer-integrated manufacturing of nanophase oxides by combining a high rate nanopowder production technology with laser diagnostics and computer modeling. (C) 1997 Acta Metallurgica Inc.