Hostname: page-component-586b7cd67f-gb8f7 Total loading time: 0 Render date: 2024-11-28T00:19:56.820Z Has data issue: false hasContentIssue false
  • English
  • Français

Synthesis of ultra-fine iron powder by combining the flame aerosol synthesis and postreduction

Published online by Cambridge University Press:  08 November 2019

Zili Zhang ,
Hui Tian ,
Shuiqing Li  and
Qiuliang Wang
Zili Zhang
Affiliation:
Institute of Electrical Engineering, Chinese Academy of Sciences, Beijing 100190, China
Hui Tian
Affiliation:
Center for Combustion Energy, Department of Energy and Power Engineering, Tsinghua University, Beijing 100084, China
Shuiqing Li*
Affiliation:
Key Laboratory for Thermal Science and Power Engineering of Ministry of Education, Department of Energy and Power Engineering, Tsinghua University, Beijing 100084, China
Qiuliang Wang*
Affiliation:
Institute of Electrical Engineering, Chinese Academy of Sciences, Beijing 100190, China; and University of Chinese Academy of Sciences, Beijing 100049, China
*
a)Address all correspondence to these authors. e-mail: [email protected]
b)e-mail: [email protected]
Get access

Abstract

The global market requirement of ultra-fine iron powder (UFIP), with a range size of 0.1–1 μm, is more than 20,000 tons per annum. However, no low-cost nontoxic synthesis route of UFIP is known. In this study, we used the low-cost, rapid, and scalable flame aerosol synthesis (FAS) method to synthesize iron oxide nanoparticles with different size and morphology. Combining with a postreduction heat treatment process, a feasible synthesis route of UFIP which meets the commercial production criteria has been developed. By optimizing the precursor concentration and postreduction heat treatment parameters, the final particle size of UFIP can be controlled. The evolution of the microstructure, phase formation, and magnetic properties during the postreduction heat treatment are systematically investigated, and a feasible reaction model has been established. This work provides an important starting point for the facile commercial synthesis of UFIP and can be readily expanded to other pure metals.

Keywords

nanostructureflame synthesismagnetic properties
Type
Article
Information
Journal of Materials Research , Volume 34 , Issue 23 , 16 December 2019 , pp. 3964 - 3974
Copyright
Copyright © Materials Research Society 2019 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

Morimoto, H. and Shakouchi, T.: Classification of ultra fine powder by a new pneumatic type classifier. Powder Technol. 131, 71 (2003).CrossRefGoogle Scholar
Gao, J.S., Arunagiri, T., Chen, J.J., and Chyan, O.: Preparation and characterization of metal nanoparticles on a diamond surface. J. Mater. Sci. 12, 3495 (2005).Google Scholar
Fujiki, A.: Present state and future prospects of powder metallurgy parts for automotive applications. Mater. Chem. Phys. 67, 298 (2001).CrossRefGoogle Scholar
Brittenham, G.M., Klein, H.G., Kushner, J.P., and Ajioka, R.S.: Preserving the national blood supply. Hematol. 2001, 422 (2001).CrossRefGoogle Scholar
Gutfleisch, O., Willard, M.A., and Bruck, E.: Magnetic materials and devices for the 21st century: Stronger, lighter, and more energy efficient. Adv. Mater. 23, 821 (2011).CrossRefGoogle ScholarPubMed
Carpenter, E.E.: Iron nanoparticles as potential magnetic carriers. J. Magn. Magn. Mater. 225, 17 (2001).CrossRefGoogle Scholar
Bumb, A., Brechbiel, M.W., Choyk, P.L., Fugger, L., Eggeman, A., Prabhakaran, D., Hutchinson, J., and Dobson, P.J.: Synthesis and characterization of ultra-small superparamagnetic iron oxide nanoparticles thinly coated with silica. Nanotechnology 19, 277 (2008).CrossRefGoogle ScholarPubMed
Kong, L.B., Liu, Z.W., Liu, L., Huang, R., Abshinova, M., Yang, Z.H., Tang, C.B., Tan, P.K., Deng, C.R., and Matitsine, S.: Recent progress in some composite materials and structures for specific electromagnetic applications. Int. Mater. Rev. 58, 203–259 (2013).CrossRefGoogle Scholar
Fultz, B., Robertson, J.L., Stephens, T.A., Nagel, L.J., and Spooner, S.: Phonon density of states of nanocrystalline Fe prepared by high-energy ball milling. J. Appl. Phys. 79, 8318 (1996).CrossRefGoogle Scholar
Abhilash, S.R., Saini, S.K., and Kabiraj, D.: Methods adopted for improving the collection efficiency in vacuum evaporation technique. J. Radioanal. Nucl. Chem. 299, 1137 (2014).CrossRefGoogle Scholar
Mates, S.P., Ridder, S.D., Biancaniello, F.S., and Zahrah, T.: Vacuum-assisted gas atomization of liquid metal. Atomization Sprays 22, 581 (2012).CrossRefGoogle Scholar
Strobel, R. and Pratsinis, S.E.: Flame aerosol synthesis of smart nanostructured materials. J. Mater. Chem. 17, 4743 (2007).CrossRefGoogle Scholar
Kammler, H.K., Beaucage, G., Kohls, D.J., Agashe, N., and Ilavsky, J.: Monitoring simultaneously the growth of nanoparticles and aggregates by in situ ultra-small-angle X-ray scattering. J. Appl. Phys. 97, 054309 (2005).CrossRefGoogle Scholar
Tani, T., Madler, L., and Pratsinis, S.E.: Synthesis of zinc oxide/silica composite nanoparticles by flame spray pyrolysis. J. Mater. Sci. 37, 4627 (2002).CrossRefGoogle Scholar
Pratsinis, S.E., Zhu, W.H., and Vemury, S.: The role of gas mixing in flame synthesis of titania powders. Powder Technol. 86, 87 (1996).CrossRefGoogle Scholar
Johannessen, T., Pratsinis, S.E., and Livbjerg, H.: Computational analysis of coagulation and coalescence in the flame synthesis of titania particles. Powder Technol. 118, 242 (2001).CrossRefGoogle Scholar
Gröhn, A.J., Pratsinis, S.E., Sánchez-Ferrer, A., Mezzenga, R., and Wegner, K.: Scale-up of nanoparticle synthesis by flame spray pyrolysis: The high-temperature particle residence time. Ind. Eng. Chem. Res. 53, 10734 (2014).CrossRefGoogle Scholar
Bakrania, S.D., Perez, C., and Wooldridge, M.S.: Methane-assisted combustion synthesis of nanocomposite tin dioxide materials. Proc. Combust. Inst. 31, 1797 (2007).CrossRefGoogle Scholar
Bakrania, S.D., Miller, T.A., Perez, C., and Wooldridge, M.S.: Combustion of multiphase reactants for the synthesis of nanocomposite materials. Combust. Flame 148, 76 (2007).10.1016/j.combustflame.2006.08.008CrossRefGoogle Scholar
Li, D., Teoh, W.Y., Selomulya, C., Woodward, R.C., Amal, R., and Rosche, B.: Flame-sprayed superparamagnetic bare and silica-coated maghemite nanoparticles: Synthesis, characterization, and protein adsorption-desorption. Chem. Mater. 18, 6403 (2006).CrossRefGoogle Scholar
Zhao, N. and Gao, M.: Magnetic Janus particles prepared by a flame synthetic approach: Synthesis, characterizations and properties. Adv. Mater. 21, 84 (2009).CrossRefGoogle Scholar
Grimm, S., Schultz, M., Barth, S., and Muller, R.: Flame pyrolysis—A preparation route for ultrafine pure gamma-Fe2O3 powders and the control of their particle size and properties. J. Mater. Sci. 32, 1083 (1997).CrossRefGoogle Scholar
Strobel, R. and Pratsinis, S.E.: Direct synthesis of maghemite, magnetite and wustite nanoparticles by flame spray pyrolysis. Adv. Powder Technol. 20, 190 (2009).CrossRefGoogle Scholar
Rao, P.M. and Zheng, X.L.: Unique magnetic properties of single crystal gamma-Fe2O3 nanowires synthesized by flame vapor deposition. Nano Lett. 11, 2390 (2011).CrossRefGoogle ScholarPubMed
Starsich, F.H.L., Sotiriou, G.A., Wurnig, M.C., Eberhardt, C., Hirt, A.M., Boss, A., and Pratsinis, S.E.: Silica-coated nonstoichiometric nano Zn-ferrites for magnetic resonance imaging and hyperthermia treatment. Adv. Healthcare Mater. 5, 2698 (2016).CrossRefGoogle ScholarPubMed
Li, S.Q., Ren, Y.H., Biswas, P., and Tse, S.D.: Flame aerosol synthesis of nanostructured materials and functional devices: Processing, modeling, and diagnostics. Prog. Energy Combust. 55, 1 (2016).CrossRefGoogle Scholar
Seo, H., Ogata, M., and Fukuyama, H.: Aspects of the Verwey transition in magnetite. Phys. Rev. B 65, 085107 (2002).CrossRefGoogle Scholar
Ohldag, H., Scholl, A., Nolting, F., Arenholz, E., Maat, S., Young, A.T., Carey, M., and Stöhr, J.: Correlation between exchange bias and pinned interfacial spins. Phys. Rev. Lett. 91, 017203 (2003).CrossRefGoogle ScholarPubMed
Wang, S.H. and Huang, Y.: Flame aerosol synthesis of WO3/CeO2 from aqueous solution: Two distinct pathways and structure design. Chem. Eng. Sci. 52, 436 (2016).Google Scholar
Supplementary material: File

Zhang et al. supplementary material

Zhang et al. supplementary material

Download Zhang et al. supplementary material(File)
File 4.3 MB