Cu-Sn binary metal particle generation by spray pyrolysis

Abstract

Cu-Sn binary particles were generated via spray pyrolysis from metal salt precursors with ethylene glycol as the co-solvent and reducing agent. The morphology, crystallinity, and elemental distribution of particles were tunable by changing the reaction temperature, residence time, and quench gas flow rate. Hollow porous particles were fabricated with a higher Sn concentration on the particle surface when the furnace set point was 500 C, while solid particles with a lower surface Sn concentration were generated when the furnace set point was 1000 C. Particles with spherical morphologies were obtained at long residence time conditions (4.5 s). Cu-Sn binary particles with irregular structures (e.g., pores on the particle surface, fragmented spherical particles, and lamellar fragments) were formed at short residence time conditions (0.92 s). A possible spray pyrolysis mechanism was proposed that incorporates chemical reaction steps and structural progression. By this mechanism, the metal salts are believed to sequentially undergo hydrolysis to metal hydroxides, decomposition to metal oxides, reduction to metals, and finally diffusion of Sn into the Cu matrix to generate the Cu-Sn solid solution.

Rational Design of Core–Shell-Structured Particles by a One-Step and Template-Free Process for High-Performance Lithium/Sodium-Ion Batteries

“…High processing temperature favors the formation of denser product particles, which has also been observed in other aerosol processes. 28,36 As shown in Figures 1, S3, and S4, the core−shell-structured particle has an average diameter of 680 nm and the average ratio of particle to core is 2.2, implying that this core−shell particle can tolerate 1064% volume expansion of the core during the charge/discharge process. The formation of a carbon shell is also supported by the Raman spectrum (Figure S5), with characteristic peaks representing the D and G band of carbon.…”

“…The set points of the furnaces were 1273 K. At the end of this continuous process, the product particles were cooled by N 2 gas and collected on a poly­(tetrafluoroethylene) (PTFE) filter. On the basis of the temperature profile of the same equipment at these conditions, the residence time of this process is 1.2 s …”

“…The set points of the furnaces were 1273 K. At the end of this continuous process, the product particles were cooled by N 2 gas and collected on a poly(tetrafluoroethylene) (PTFE) filter. On the basis of the temperature profile of the same equipment at these conditions, the residence time of this process is 1.2 s. 36 Electrode Preparation and Electrochemical Measurements in Li/Na-Ion Batteries. Electrochemical measurements were performed using coin cells (CR2032) assembled in an argon-filled glovebox (<1 ppm of water and oxygen).…”

Process Engineering to Increase the Layered Phase Concentration in the Immediate Products of Flame Spray Pyrolysis

“…We found that lithium was accumulated on the wall of the instrument after analyzing the clean-in-place powders. As the thermophoresis was correlated to the temperature difference between the gas flow and the tube wall, we set the temperature of the tube furnace to 973 K to reduce the lithium loss. The last effort was introducing a rapid quench gas after the flame.…”

Nanoalloy Materials for Chemical Catalysis

“…However, the particle size is generally large and is hard to reduce limited by the aerosol droplets. By this route, FeNi and CuSn BMNAs with tunable sizes and compositions have been prepared …”