The formation of metastable phases in plasma-and flame-prepared alumina particles is examined in terms of the classical nucleation theory, rate of transformation of metastaNe to stable forms, and the thermal history of the particles during solidification. It is suggested that homogeneous nucleation of the solidification of liquid droplets at considerable undercooling results in the formation of ~,-AI203 rather than c~-Al=O3 because of its lower critical free energy for nucleation. The phase finally observed depends upon the thermal history of the particles during evolution of the heat of fusion and upon the kinetics of the transformation of the nucleating phase to the stable phase. This means that the cooling rate of the particles is relatively unimportant and under the conditions existing in flames and plasmas, metastable alumina will be formed on solidification. The metastable form will be retained on cooling particles less than approximately 10 gm diameter, but particles larger than this may transform to ~-AI203 during the solidification exotherm oxidation of aluminium chloride, have been reported to consist predominantly of metastable phases 0,-A1203, S-A120~ and 0-A1203) rather than the stable c~-A12Oa form. Plasma-sprayed coatings also consist of metastable forms [6,7] although if deposited onto a heated substrate, some a-A1203 is produced [8].Plummer [1 ] observed that a-A1203 tended to be produced in flame spheroidizedparticleslarger than approximately 15 gm diameter and he suggested that metastable phases were formed at fine particle sizes because their more rapid cooling rate resulted in "quenching in" of the assumed tetrahedral co-ordination of aluminium by oxygen in the liquid state. This would then tend to produce solid phases with cubic close packing of oxygen ions 0'-, 8-, 0-A12Oa) rather than the hexagonal packing of ~-A12Oa. Das and Fulrath [2] also observed that although a metastable form (7-A1203) predominated in particles less than 10 jam diameter spheroidized in a d.c. plasma jet, o~-A1203 was formed at larger particle