Gas phase sodium flame synthesis of non-oxide metallic powders

Demand for new high surface area non-oxide materials is growing to support diverse markets such as energy storage, catalysts, and electronic materials. Tight control of powder purity and flow properties is important for high performing components. In particular oxygen impurities can adversely affect part physical properties of high value metals such as titanium and tantalum. Here we describe an advanced materials synthesis process for producing nonoxide metals, alloys, ceramics, intermetallics and metal matrix composites. Sodium vapor reacts hypergolically with metal chlorides to form high surface area powder with primary particle size less than 30 nm. These powders are salt encapsulated, of very high purity, and sinter active. Tight control of powder size distribution and morphology can be achieved. The flame synthesis process is continuous and inherently scalable. Potential uses for flame synthesized feed powders for capacitors, catalysts and Additive Manufacturing (AM) applications are also reviewed.