Flash synthesis of zirconia nanoparticles by microwave forced hydrolysis

Forced hydrolysis preparation of zirconia sols and powders by microwave heating of zirconium tetrachloride solutions at temperatures equal to 180 °C leads in a few minutes to monodispersed nanoscale zirconia particles. Synthesis was performed in a microwave reactor called the RAMO system. This microwave reactor was designed by the authors. This flash-synthesis process combines the advantages of forced hydrolysis (homogeneous precipitation) and microwave heating (very fast heating rates). The sols and powders were characterized by x-ray diffraction,photon correlation spectroscopy (PCS), small-angle x-ray scattering, and transmission electron microscopy. Sols are colloidally stable, which means that after 6 months no sedimentation is observed and the size distribution given by PCS measurements has not changed. For all synthesis conditions (with or without HCl, zirconium salt concentration, and synthesis time), zirconia polycrystalline particles were produced. According to the different analyses, these zirconia polycrystalline particles were constituted of aggregates of small primary clusters.