Abstract: A low pressure combustion flame method for the production of nanophase powders, coatings and free-standing forms. The process involves controlled thermal decomposition of one or more metalorganic precursors in a flat-flame combustor unit in which both temperature distribution and gas phase residence time are uniform over the entire surface of the burner. It is this feature that makes the combustion flame reactor such a versatile tool for (1) high rate production of loosely agglomerated nanoparticle powders with controlled particle size and distribution, (2) uniform deposition of shape conformal nanophase coatings, and (3) net-shaped fabrication of nanocrystalline free-standing forms such as sheets, rings and drums. Applications for this new nanomaterials processing technology include electrical, thermal, optical, display, magnetic, catalytic, tribological and structural materials.

Abstract: An apparatus of forming non-agglomerated nanostructured ceramic (n-ceramic) powders from metalorganic precursors combines rapid thermal decomposition of a precursor/carrier gas stream in a hot tubular reactor with rapid condensation of the product particles on a cold substrate under a reduced inert gas pressure of 1-50 mbar. A wide variety of metalorganic precursors is available. The apparatus is particularly suitable for formation of n-SiC.sub.x N.sub.y powders from hexamethyl-disilizane or the formation of n-ZrO.sub.x C.sub.y powders from zirconium tertiary butoxide. The n-SiC.sub.x N.sub.y compounds can be further reacted to form SiC or Si.sub.3 N.sub.4 whiskers, individually or in random-weave form, by heating in a hydrogen or ammonia atmosphere. The non-agglomerated n-ceramic powders form uniformly dense powder compacts by cold pressing which can be sintered to theoretical density at temperatures as low as 0.5 Tm.