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Aluminum nanoparticles (Al NPs) are interesting for energetic and plasmonic applications due to their enhanced size-dependent properties. Passivating the surface of these particles is necessary to avoid forming a native oxide layer, which can degrade energetic and optical characteristics. This work utilized a radiofrequency (RF)-driven capacitively coupled argon/hydrogen plasma to form surface-modified Al NPs from aluminum trichloride (AlCl3) vapor and 5% silane in argon (dilute SiH4). Varying the power and dilute SiH4 flow rate in the afterglow of the plasma led to the formation of varying nanoparticle morphologies: Al–SiO2 core–shell, Si–Al2O3 core–shell, and Al–Si Janus particles. Scanning transmission electron microscopy with a high-angle annular dark-field detector (STEM-HAADF) and energy-dispersive X-ray spectroscopy (EDS) were employed for characterization. The surfaces of the nanoparticles and sample composition were characterized and found to be sensitive to changes in RF power input and dilute SiH4 flow rate. This work demonstrates a tunable range of Al–SiO2 core–shell nanoparticles where the Al-to-Si ratio could be varied by changing the plasma parameters. Thermal analysis measurements performed on plasma-synthesized Al, crystalline Si, and Al–SiO2 samples are compared to those from a commercially available 80 nm Al nanopowder. Core–shell particles exhibit an increase in oxidation temperature from 535 °C for Al to 585 °C for Al–SiO2. This all-gas-phase synthesis approach offers a simple preparation method to produce high-purity heterostructured Al NPs. 

Bimetallic nanomaterials have shown great potential across various fields of application. However, the synthesis of many bimetallic particles can be challenging due to the immiscibility of their constituent metals. In this study, we present a synthetic strategy to produce compositionally tunable silver–copper (Ag-Cu) bimetallic nanoparticles using plasma-driven liquid surface chemistry. By using a low-pressure nonthermal radiofrequency (RF) plasma that interacts with an Ag-Cu precursor solution at varying electrode distances, we identified that the reduction of Ag and Cu salts is governed by two “orthogonal” parameters. The reduction of Cu2+ is primarily influenced by plasma electrons, whereas UV photons play a key role in the reduction of Ag+. Consequently, by adjusting the electrode distance and the precursor ratios in the plasma–liquid system, we could control the composition of Ag-Cu bimetallic nanoparticles over a wide range. 

Abstract The in-flight reduction of iron ore particles using an atmospheric pressure hydrogen plasma is investigated. Iron ore particles with a size less than 75 µm are aerosolized and carried with an argon-hydrogen (90%–10%) gas mixture through an atmospheric pressure microwave plasma. After the treatment, the collected particles are observed to follow three distinct populations: (i) fully reduced nanoparticles, (ii) partially reduced spheres, larger than the feedstock, and (iii) partially melted, partly reduced agglomerates. A model is developed to explain the possible mechanism for the origin of the three populations. The nanoparticles (i) are found to be likely formed from the previously evaporated material whereas the particles (ii) and (iii) result from the partial/complete melting of the particles and agglomerates flowing through the reactor. The gas temperature is estimated to be more than 2000 K, which enables the rapid melting, evaporation, and reduction of these particles within residence times of only a few 10 ms. 

Gamma alumina (γ-Al2O3) is widely used as a catalyst and catalytic support due to its high specific surface area and porosity. However, synthesis of γ-Al2O3 nanocrystals is often a complicated process requiring high temperatures or additional post-synthetic steps. Here, we report a single-step synthesis of size-controlled and monodisperse, facetted γ-Al2O3 nanocrystals in an inductively coupled nonthermal plasma reactor using trimethylaluminum and oxygen as precursors. Under optimized conditions, we observed phase-pure, cuboctahedral γ-Al2O3 nanocrystals with defined surface facets. Nuclear magnetic resonance studies revealed that nanocrystal surfaces are populated with AlO6, AlO5 and AlO4 units with clusters of hydroxyl groups. Nanocrystal size tuning was achieved by varying the total reactor pressure yielding particles as small as 3.5 nm, below the predicted thermodynamic stability limit for γ-Al2O3. 

Abstract Uniform-size, non-native oxide-passivated metallic aluminum nanoparticles (Al NPs) have desirable properties for fuel applications, battery components, plasmonics, and hydrogen catalysis. Nonthermal plasma-assisted synthesis of Al NPs was previously achieved with an inductively coupled plasma (ICP) reactor, but the low production rate and limited tunability of particle size were key barriers to the applications of this material. This work focuses on the application of capacitively coupled plasma (CCP) to achieve improved control over Al NP size and a ten-fold increase in yield. In contrast with many other materials, where NP size is controlled via the gas residence time in the reactor, the Al NP size appeared to depend on the power input to the CCP system. The results indicate that the CCP reactor assembly, with a hydrogen-rich argon/hydrogen plasma, was able to produce Al NPs with diameters that were tunable between 8 and 21 nm at a rate up ∼ 100 mg h⁻¹. X-ray diffraction indicates that a hydrogen-rich environment results in crystalline metal Al particles. The improved synthesis control of the CCP system compared to the ICP system is interpreted in terms of the CCP’s lower plasma density, as determined by double Langmuir probe measurements, leading to reduced NP heating in the CCP that is more amenable to NP nucleation and growth.