We report a new method for the high rate formation of nanophase ZrO 2 and Al 2 O 3 powders. In the experimental arrangement, a solution of metal alkoxides in their parent alcohols is converted into an aerosol of approximately 30 ¹ diameter droplets by means of an ultrasonic spray nozzle. The aerosol is mixed with oxygen immediately after formation and combusted in a specially designed burner at high temperature. The resulting oxide particles are thermophoretically collected and examined using TEM and X-ray diffractometry. A novel, patented, burner design permits a signicant reduction in temperature gradients normal to the ame. As a consequence, it is possible to obtain signi cantly better control over particle size and morphology and, in addition, hard agglomerates are absent. This is a signi cant departure from the process found in a typical ame reactor. With this technique, spherical, unnecked particles in the range from 5 to 140 nm (peaking sharply at 40 nm) are produced. There is no correlation between the initial liquid droplet size and the nal particle size. The method was successfully applied to the formation of zirconium and aluminum oxide at synthesis rates in excess of 3 g/min. Experiments to measure the ame temperature using an optical technique yielded temperatures between 2300 K and 3000 K, depending on the position in the ame and the type of precursor solution used. We note that this technique can be readily extended to more complex oxides such as YAG and BaSrTiO 3 .
INTRODUCTIONDuring the past several years a large number of methods for the production of nanoscale oxide particles have been reported. Oxide powders with particles sizes in the range below 100 nm are important in many applications that include ceramic products, catalysts, and paint opaci ers. The approaches taken in their synthesis can be divided into wet chemical and gas phase (aerosol) methods. Among the former is the precipitation of particles from a suitable homogeneous precursor solution (Ciftcioglo and Majo 1990) and the wet hydrolysis of metal alkoxides in solution (Smith et al.; Ingebrethsen and Matijevi).