Nanomaterial powders and deposits prepared by flame spray processing of liquid precursors

Ultrafine grained Al2O3, Mn2O3, ZrO2 and Y2O3-ZrO2 powders and deposits were produced by flame spray processing of atomized precursor solutions. Ceramic particles of 1–150 nm size were collected on an electrostatic precipitator at a rate of ~ 5–20 mg/min, with ~ 5–25% collection efficiency. Nanograined oxide deposits with a powder morphology were produced at a deposition efficiency of < 10%. The spray feedstock and processing conditions affected the size, shape and phase composition of the synthesized nanomaterials. Particles with wider distributions of larger size grains were produced from aqueous solutions, whereas narrow range of fine-grained material was produced from organo-metallic precursors. Liquid flame spraying is a viable technique to produce nanoparticles and deposits.