Controlling thermophoresis in the exothermic nitridation of an aluminum aerosol

Thermophoretic deposition in an exothermic aluminum (AI) nitridation aerosol process was redirected from the reactor wall to a flowing inert powder when the inert powder was admixed with the feed atomized AI. The inert powder can be a compatible (aluminum nitride) or removable (carbon) powder, which provides for a lower-temperature surface to be in close proximity to the exothermic reaction sites. Aluminum nitride manufactured by this process was pressurelessly sintered with 3 wt% Y2O3 to fabricate dense AIN parts exhibiting high thermal conductivity (141 W/m – K).