Ultrasonic Spray Pyrolysis for Synthesis of Spherical Zirconia Particles

This paper presents new findings on ultrasonic spray pyrolysis of zirconium hydroxyl acetate precursor drops whose sizes were precisely measured using laser light diffraction technique. Precursor concentration plays a predominant role in determination of product particle size. At 0.01 wt% precursor concentration, conventional spray pyrolysis at 750°C using precursor drops 5–8 !m in diameter, generated by an ultrasonic nebulizer at 2.66 MHz, yielded uniform spherical yttriastabilized zirconia (YSZ) particles 73 nm in diameter measured by scanning electron microscopy. The YSZ particle diameters were much smaller than those predicted by the one-particle-per-drop mechanism. Under similar reaction conditions, the high-throughput ultrasound-modulated two-fluid (UMTF) spray pyrolysis of larger precursor drops (28-!m peak diameter) also yielded spherical dense particles; they were significantly smaller in size than those produced by the low-throughput conventional ultrasonic spray pyrolysis of smaller drops (6.8-!m peak diameter).