Continuous synthesis of high-entropy alloy nanoparticles by in-flight alloying of elemental metals

Keun Su Kim (), Martin Couillard, Ziqi Tang, Homin Shin, Daniel Poitras, Changjun Cheng, Olga Naboka, Dean Ruth, Mark Plunkett, Lixin Chen, Liliana Gaburici, Thomas Lacelle, Michel Nganbe and Yu Zou
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Keun Su Kim: National Research Council Canada
Martin Couillard: National Research Council Canada
Ziqi Tang: University of Ottawa
Homin Shin: National Research Council Canada
Daniel Poitras: National Research Council Canada
Changjun Cheng: University of Toronto
Olga Naboka: National Research Council Canada
Dean Ruth: National Research Council Canada
Mark Plunkett: National Research Council Canada
Lixin Chen: University of Toronto
Liliana Gaburici: National Research Council Canada
Thomas Lacelle: National Research Council Canada
Michel Nganbe: University of Ottawa
Yu Zou: University of Toronto

Nature Communications, 2024, vol. 15, issue 1, 1-12

Abstract: Abstract High-entropy alloy (HEA) nanoparticles (NPs) exhibit unusual combinations of functional properties. However, their scalable synthesis remains a significant challenge requiring extreme fabrication conditions. Metal salts are often employed as precursors because of their low decomposition temperatures, yet contain potential impurities. Here, we propose an ultrafast ( 5000 K) is employed for rapid heating/cooling (103 − 105 K s−1), and demonstrates the synthesis of CrFeCoNiMo HEA NPs ( ~ 50 nm) at a high rate approaching 35 g h−1 with a conversion efficiency of 42%. Our thermofluid simulation reveals that the properties of HEA NPs can be tailored by the plasma gas which affects the thermal history of NPs. The HEA NPs demonstrate an excellent light absorption of > 96% over a wide spectrum, representing great potential for photothermal conversion of solar energy at large scales. Our work shows that the thermal plasma process developed could provide a promising route towards industrial scale production of HEA NPs.

Date: 2024
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DOI: 10.1038/s41467-024-45731-z

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