Nanosize particles of aluminum nitride have been successfully synthesized by a pulsed wire discharge (PWD). Intense pulsed current through an aluminum wire evaporated the wire to produce a high‐density plasma. The plasma was then cooled by an ambient gas mixture of NH3/N2, resulting in nitridation. As a result, nanosize particles of aluminum nitride were formed. The average particle diameter was found to be ∼28 nm with a geometric standard deviation of 1.29. The maximum AlN content of 97% in the powders was achieved by optimizing various parameters: the gas pressure, the ratio of NH3 and N2, the wire diameter, the pulse width, and the input electrical energy. The ratio of the AlN powder production to the electrical energy consumption was evaluated as ∼40 g/(kW·h). Thus, PWD is a very efficient and promising method to synthesize nanosize powders of AlN.
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