Plasma Synthesis of Ceramic Powders

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Abstract
Condensation from plasmas has been shown to yield very fine, high purity powders from even the most refractory materials. Elementary particles in these powders are often single crystals, as fine as 50 nm diameter. These particles vary widely in agglomeration state; in some systems they are essentially independent, while in others hard agglomerates as large as several microns are observed. In this article the geometric aspects of reactor design which are thought to influence these powder structures are reviewed, along with three case studies in powder microstructure. Finally, the structure of the “typical” plasma powder is compared with expectations from alternative preparation routes. The development of new, energy-efficient processing strategies for ceramic fabrication has become a rapid growth field over the last ten years. Most of these strategies rely on minimizing diffusion requirements during densification by improving both the chemical homogeneity and the initial density of the powder compact to be consolidated; both requirements dictate unusual care in the synthesis of the starting powders. In the oxide systems most extensively studied to date, the required powders can often be produced by precipitation from aqueous solutions and/or emulsions. In the carbide and nitride systems widely envisaged for the next generation of structural applications, these techniques are difficult and gas-phase synthesis routes appear more attractive. In fact, even the leading practitioners of the precipitation arts write enthusiastically of aerosol synthesis methods for the oxides.

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