A stable atmospheric-pressure plasma for extreme-temperature synthesis.

Plasmas can generate ultra-high-temperature reactive environments that can be used for the synthesis and processing of a wide range of materials1,2. However, the limited volume, instability and non-uniformity of plasmas have made it challenging to scalably manufacture bulk, high-temperature materials3-8. Here we present a plasma set-up consisting of a pair of carbon-fibre-tip-enhanced electrodes that enable the generation of a uniform, ultra-high temperature and stable plasma (up to 8,000 K) at atmospheric pressure using a combination of vertically oriented long and short carbon fibres. The long carbon fibres initiate the plasma by micro-spark discharge at a low breakdown voltage, whereas the short carbon fibres coalesce the discharge into a volumetric and stable ultra-high-temperature plasma. As a proof of concept, we used this process to synthesize various extreme materials in seconds, including ultra-high-temperature ceramics (for example, hafnium carbonitride) and refractory metal alloys. Moreover, the carbon-fibre electrodes are highly flexible and can be shaped for various syntheses. This simple and practical plasma technology may help overcome the challenges in high-temperature synthesis and enable large-scale electrified plasma manufacturing powered by renewable electricity.

Programmable heating and quenching for efficient thermochemical synthesis.

Conventional thermochemical syntheses by continuous heating under near-equilibrium conditions face critical challenges in improving the synthesis rate, selectivity, catalyst stability and energy efficiency, owing to the lack of temporal control over the reaction temperature and time, and thus the reaction pathways1-3. As an alternative, we present a non-equilibrium, continuous synthesis technique that uses pulsed heating and quenching (for example, 0.02 s on, 1.08 s off) using a programmable electric current to rapidly switch the reaction between high (for example, up to 2,400 K) and low temperatures. The rapid quenching ensures high selectivity and good catalyst stability, as well as lowers the average temperature to reduce the energy cost. Using CH4 pyrolysis as a model reaction, our programmable heating and quenching technique leads to high selectivity to value-added C2 products (>75% versus <35% by the conventional non-catalytic method and versus <60% by most conventional methods using optimized catalysts). Our technique can be extended to a range of thermochemical reactions, such as NH3 synthesis, for which we achieve a stable and high synthesis rate of about 6,000 µmol gFe-1 h-1 at ambient pressure for >100 h using a non-optimized catalyst. This study establishes a new model towards highly efficient non-equilibrium thermochemical synthesis.

Rapid Atomic Ordering Transformation toward Intermetallic Nanoparticles.

Chemically ordered intermetallic nanoparticles are promising candidates for energy-related applications such as electrocatalysis. However, the synthesis of intermetallics generally requires long annealing (several hours) to achieve the ordered structure, which causes nanoparticles agglomeration and diminished performance, particularly for catalysis. Herein, we demonstrate a new rapid Joule heating approach that can synthesize highly ordered and well-dispersed intermetallic nanoparticles. As a proof-of-concept, we synthesized fully ordered Pd3Pb intermetallic nanoparticles that feature small size distribution (∼6 nm). Computational analysis of the L12 Pd3Pb material suggests that this rapid atomic ordering transformation can be attributed to a vacancy-mediated diffusion mechanism. Moreover, the nanoparticles demonstrate excellent electrocatalytic activity and exceptional stability for the oxygen reduction reaction (ORR), retaining >95% of the current density over 10 h of chronoamperometry test with negligible structural and compositional changes. This study demonstrates a new strategy of providing a new direction for intermetallic synthesis and catalyst discovery.

Fabrication of Cellulose-Graphite Foam via Ion Cross-linking and Ambient-Drying.

Conventional plastic foams are usually produced by fossil-fuel-derived polymers, which are difficult to degrade in nature. As an alternative, cellulose is a promising biodegradable polymer that can be used to fabricate greener foams, yet such a process typically relies on methods (e.g., freeze-drying and supercritical-drying) that are hardly scalable and time-consuming. Here, we develop a fast and scalable approach to prepare cellulose-graphite foams via rapidly cross-linking the cellulose fibrils in metal ions-containing solution followed by ambient drying. The prepared foams exhibit low density, high compressive strength, and excellent water stability. Moreover, the cross-linking of the cellulose fibrils can be triggered by various metal ions, indicating good universality. We further use density functional theory to reveal the cross-linking effect of different ions, which shows good agreement with our experimental observation. Our approach presents a sustainable route toward low-cost, environmentally friendly, and scalable foam production for a range of applications.

Rapid Synthesis of High-Entropy Oxide Microparticles.

High-entropy nanoparticles have received notable attention due to their tunable properties and broad material space. However, these nanoparticles are not suitable for certain applications (e.g., battery electrodes), where their microparticle (submicron to micron) counterparts are more preferred. Conventional methods used for synthesizing high-entropy nanoparticles often involve various ultrafast shock processes. To increase the size thereby achieving high-entropy microparticles, longer reaction time (e.g., heating duration) is usually used, which may also lead to undesired particle overgrowth or even densified microstructures. In this work, an approach based on Joule heating for synthesizing high-entropy oxide (HEO) microparticles with uniform elemental distribution is reported. In particular, two key synthesis conditions are identified to achieve high-quality HEO microparticles: 1) the precursors need to be loosely packed to avoid densification; 2) the heating time needs to be accurately controlled to tens of seconds instead of using milliseconds (thermal shock) that leads to nanoparticles or longer heating duration that forms bulk structures. The utility of the synthesized HEO microparticles for a range of applications, including high-performance Li-ion battery anode and water oxidation catalyst. This study opens up a new door toward synthesizing high-entropy microparticles with high quality and broad material space.

Rapid Pressureless Sintering of Glasses.

Silica glasses have wide applications in industrial fields due to their extraordinary properties, such as high transparency, low thermal expansion coefficient, and high hardness. However, current methods of fabricating silica glass generally require long thermal treatment time (up to hours) and complex setups, leading to high cost and slow manufacturing speed. Herein, to obtain high-quality glasses using a facile and rapid method, an ultrafast high-temperature sintering (UHS) technique is reported that requires no additional pressure. Using UHS, silica precursors can be densified in seconds due to the large heating rate (up to 102 K s-1 ) of closely placed carbon heaters. The typical sintering time is as short as ≈10 s, ≈1-3 orders of magnitude faster than other methods. The sintered glasses exhibit relative densities of > 98% and high visible transmittances of ≈90%. The powder-based sintering process also allows rapid doping of metal ions to fabricate colored glasses. The UHS is further extended to sinter other functional glasses such as indium tin oxide (ITO)-doped silica glass, and other transparent ceramics such as Gd-doped yttrium aluminum garnet. This study demonstrates an UHS proof-of-concept for the rapid fabrication of high-quality glass and opens an avenue toward rapid discovery of transparent materials.

Continuous Fly-Through High-Temperature Synthesis of Nanocatalysts.

The conventional thermal treatment systems typically feature low ramping/cooling rates, which lead to steep thermal gradients that generate inefficient, nonuniform reaction conditions and result in nanoparticle aggregation. Herein, we demonstrate a continuous fly-through material synthesis approach using a novel high-temperature reactor design based on the emerging thermal-shock technology. By facing two sheets of carbon paper with a small distance apart (1-3 mm), uniform and ultrahigh temperatures can be reached up to 3200 K within 50 ms by simply applying a voltage of 15 V. The raw materials can be continuously fed through the device, allowing the final products to be rapidly collected. As a proof-of-concept demonstration, we synthesized Pt nanocatalysts (∼4 nm) anchored on carbon black via this reactor at ∼1400 K. Furthermore, we find it features excellent electrocatalytic activities toward methanol oxidation reaction. This work offers a highly efficient platform for nanomaterials synthesis at high temperatures.

Strong, Hydrostable, and Degradable Straws Based on Cellulose-Lignin Reinforced Composites.

The huge consumption of single-use plastic straws has brought a long-lasting environmental problem. Paper straws, the current replacement for plastic straws, suffer from drawbacks, such as a high cost of the water-proof wax layer and poor water stability due to the easy delamination of the wax layer. It is therefore crucial to find a high-performing alternative to mitigate the environmental problems brought by plastic straws. In this paper, all natural, degradable, cellulose-lignin reinforced composite straws, inspired by the reinforcement principle of cellulose and lignin in natural wood are developed. The cellulose-lignin reinforced composite straw is fabricated by rolling up a wet film made of homogeneously mixed cellulose microfibers, cellulose nanofibers, and lignin powders, which is then baked in oven at 150 °C. When baked, lignin melts and infiltrates the micro-nanocellulose network, acting as a polyphenolic binder to improve the mechanical strength and hydrophobicity performance of the resulting straw. The obtained straws demonstrate several advantageous properties over paper straws, including 1) excellent mechanical performance, 2) high hydrostability, and 3) low cost. Moreover, the natural degradability of the cellulose-lignin reinforced composite straws makes them promising candidates to replace plastic straws and suggests possible substitutes for other petroleum-based plastics.

High-Temperature Pulse Method for Nanoparticle Redispersion.

Nanoparticles suffer from aggregation and poisoning issues (e.g., oxidation) that severely hinder their long-term applications. However, current redispersion approaches, such as continuous heating in oxidizing and reducing environments, face challenges including grain growth effects induced by long heating times as well as complex procedures. Herein, we report a facile and efficient redispersion process that enables us to directly transform large aggregated particles into nanoscale materials. In this method, a piece of carbon nanofiber film was used as a heater and high treatment temperature (∼1500-2000 K) is rapidly elevated and maintained for a very short period of time (100 ms), followed by fast quenching back to room temperature at a cooling rate of 105 K/s to inhibit sintering. With these conditions we demonstrate the redispersion of large aggregated metal oxide particles into metallic nanoparticles just ∼10 nm in size, uniformly distributed on the substrate. Furthermore, the metallic states of the nanoparticles are renewed during the heat treatment through reduction. The redispersion process removes impurities and poisoning elements, yet is able to maintain the integrity of the substrate because of the ultrashort heating pulse time. This method is also significantly faster (ca. milliseconds) compared to conventional redispersion treatments (ca. hours), providing a pragmatic strategy to redisperse degraded particles for a variety of applications.

Thermal Shock Synthesis of Nanocatalyst by 3D-Printed Miniaturized Reactors.

High temperature synthesis and treatments are ubiquitous in chemical reactions and material manufacturing. However, conventional sintering furnaces are bulky and inefficient with a narrow temperature range (<1500 K) and slow heating rates (<100 K min-1 ), which are undesirable for many applications that require transient heating to produce ideal nanostructures. Herein, a 3D-printed, miniaturized reactor featuring a dense micro-grid design is developed to maximize the material contact and therefore acheive highly efficient and controllable heating. By 3D printing, a versatile, miniaturized reactor with microscale features can be constructed, which can reach a much wider temperature range (up to ≈3000 K) with ultrafast heating/cooling rates of ≈104 K s-1 . To demonstrate the utility of the design, rapid and batch synthesis of Ru nanoparticles supported in ordered mesoporous carbon is performed by transient heating (1500 K, 500 ms). The resulting ultrafine and uniform Ru nanoparticles (≈2 nm) can serve as a cathode in Li-CO2 batteries with good cycling stability. The miniaturized reactor, with versatile shape design and highly controllable heating capabilities, provides a platform for nanocatalyst synthesis with localized and ultrafast heating toward high temperatures that is otherwise challenging to achieve.

Lignin-Based Direct Ink Printed Structural Scaffolds.

3D printing of lignocellulosic biomass (cellulose, hemicellulose, and lignin) has attracted increasing attention by using this abundant, sustainable, and ecofriendly material. While cellulose can be easily tailored into a highly viscous ink for 3D printing, after solvent evaporation, the final printed structures become highly porous, fragile, and easily fall apart in water due to its hydrophilic nature. Lignin, another crucial component of natural lignocellulose, has not yet been reported for ink printing due to its unfavorable rheological behavior. Herein, a low-cost direct ink printing strategy is developed to fabricate lignin-based 3D structures with lignin no further refined and a more compact microstructure as well as different functionalities compared with printed cellulose. By using a soft triblock copolymer as the crosslinking agent, the rheology of lignin-based inks can be adjusted from soft to rigid, and even enables vertical printing which requires stiff and self-supporting features. The lignin-based inks contain less water (≈40 wt%) and exhibit a much denser, stiffer structure, resulting in a wet tensile strength of ≈30 MPa, compared to only ≈0.6 MPa for printed cellulose. In addition, the unique macromolecular structure of lignin also demonstrates significantly improved stability in water and under heat, as well as UV-blocking performance.

Rapid, High-Temperature, In Situ Microwave Synthesis of Bulk Nanocatalysts.

Carbon-black-supported nanoparticles (CNPs) have attracted considerable attention for their intriguing catalytic properties and promising applications. The traditional liquid synthesis of CNPs commonly involves demanding operation conditions and complex pre- or post-treatments, which are time consuming and energy inefficient. Herein, a rapid, scalable, and universal strategy is reported to synthesize highly dispersed metal nanoparticles embedded in a carbon matrix via microwave irradiation of carbon black with preloaded precursors. By optimizing the amount of carbon black, the microwave absorption is dramatically improved while the thermal dissipation is effectively controlled, leading to a rapid temperature increase in carbon black, ramping to 1270 K in just 6 s. The whole synthesis process requires no capping agents or surfactants, nor tedious pre- or post-treatments of carbon black, showing tremendous potential for mass production. As a proof of concept, the synthesis of ultrafine Ru nanoparticles (≈2.57 nm) uniformly embedded in carbon black using this microwave heating technique is demonstrated, which displays remarkable electrocatalytic performance when used as the cathode in a Li-O2 battery. This microwave heating method can be extended to the synthesis of other nanoparticles, thereby providing a general methodology for the mass production of carbon-supported catalytic nanoparticles.

Growth of Sub-5 nm Metal Nanoclusters in Polymer Melt Aerosol Droplets.

Ultrasmall metal nanoparticles are inherently unstable because of their high specific surface area. This work investigates how growth and aggregation of these nanostructures can be circumvented by incorporating them into a polymer matrix in an on-the-fly growth process. We demonstrate the formation of sub-5 nm particles of Ni, Co, and Cu nanoparticles in a polymer matrix using an aerosol single-drop reactor approach. The rapid thermal pulse given to the aerosol particles enables the formation of nuclei and growth, with subsequent rapid quenching to freeze in the structure. The role of the temperature as well as the precursor concentration of the resulting size and morphology is discussed. A characteristic time analysis and an analysis of the particle size distributions lead to the conclusion that growth is governed by nucleation and surface growth, with little coagulation or Ostwald ripening. Finally, we note that this aerosol route is amenable to scale-up for large-scale production of nanoclusters that can either be used as is within the polymer or released by solvent extraction, depending on the application.

What atomic properties of metal oxide control the reaction threshold of solid elemental fuels?

The redox reaction between fuel (metal, metalloid, etc.) and metal oxide is ubiquitous. On the other hand simple thermodynamic considerations do not seem to yield much insight into what makes for a vigorous oxidizer. In this study, two different systematically doped metal oxide systems: perovskites (9 compounds) and δ-Bi2O3 (12 compounds) were synthesized in a manner such that for each system the crystal structure and morphology were maintained. Four fuels (Al, B, Ta, C) with different physical properties, covering almost all fuel types, were included in this study. The initiation temperature and oxygen release temperature was measured by fast heating (>105 K s-1) temperature-jump/time-of-flight mass spectrometry coupled with high-speed imaging. These results were then correlated with the average metal-oxygen bond energy in the oxidizer, and overall metal-oxygen electronegativity. In general, within each systematic metal oxide, we found linear relationships between average bond energy and electronegativity of the metal oxides with initiation temperature for all four fuels, despite their very different physical/chemical properties. These results indicate that intrinsic atomic properties of metal oxide control fuel-metal oxide reaction initiation.

Doped δ-bismuth oxides to investigate oxygen ion transport as a metric for condensed phase thermite ignition.

Nanothermites offer high energy density and high burn rates, but are mechanistically only now being understood. One question of interest is how initiation occurs and how the ignition temperature is related to microscopic controlling parameters. In this study, we explored the potential role of oxygen ion transport in Bi2O3 as a controlling mechanism for condensed phase ignition reaction. Seven different doped δ-Bi2O3 were synthesized by aerosol spray pyrolysis. The ignition temperatures of Al/doped Bi2O3, C/doped Bi2O3 and Ta/doped Bi2O3 were measured by temperature-jump/time-of-flight mass spectrometer coupled with a high-speed camera respectively. These results were then correlated to the corresponding oxygen ion conductivity (directly proportional to ion diffusivity) for these doped Bi2O3 measured by impedance spectroscopy. We find that ignition of thermite with doped Bi2O3 as oxidizer occurs at a critical oxygen ion conductivity (∼0.06 S cm-1) of doped Bi2O3 in the condensed-phase so long as the aluminum is in a molten state. These results suggest that oxygen ion transport limits the condensed state Bi2O3 oxidized thermite ignition. We also find that the larger oxygen vacancy concentration and the smaller metal-oxide bond energy in doped Bi2O3, the lower the ignition temperature. The latter suggests that we can consider the possibility of manipulating microscopic properties within a crystal, to tune the resultant energetic properties.

Flash heating process for efficient meat preservation.

Maintaining food safety and quality is critical for public health and food security. Conventional food preservation methods, such as pasteurization and dehydration, often change the overall organoleptic quality of the food products. Herein, we demonstrate a method that affects only a thin surface layer of the food, using beef as a model. In this method, Joule heating is generated by applying high electric power to a carbon substrate in <1 s, which causes a transient increase of the substrate temperature to > ~2000 K. The beef surface in direct contact with the heating substrate is subjected to ultra-high temperature flash heating, leading to the formation of a microbe-inactivated, dehydrated layer of ~100 µm in thickness. Aerobic mesophilic bacteria, Enterobacteriaceae, yeast and mold on the treated samples are inactivated to a level below the detection limit and remained low during room temperature storage of 5 days. Meanwhile, the product quality, including visual appearance, texture, and nutrient level of the beef, remains mostly unchanged. In contrast, microorganisms grow rapidly on the untreated control samples, along with a rapid deterioration of the meat quality. This method might serve as a promising preservation technology for securing food safety and quality.

Interface Engineering Between Multi-Elemental Alloy Nanoparticles and a Carbon Support Toward Stable Catalysts.

Multi-elemental alloy (MEA) nanoparticles have recently received notable attention owing to their high activity and superior phase stability. Previous syntheses of MEA nanoparticles mainly used carbon as the support, owing to its high surface area, good electrical conductivity, and tunable defective sites. However, the interfacial stability issue, such as nanoparticle agglomeration, remains outstanding due to poor interfacial binding between MEA and carbon. Such a problem often causes performance decay when MEA nanoparticles are used as catalysts, hindering their practical applications. Herein, an interface engineering strategy is developed to synthesize MEA-oxide-carbon hierarchical catalysts, where the oxide on carbon helps disperse and stabilize the MEA nanoparticles toward superior thermal and electrochemical stability. Using several MEA compositions (PdRuRh, PtPdIrRuRh, and PdRuRhFeCoNi) and oxides (TiO2 and Cr2 O3 ) as model systems, it is shown that adding the oxide renders superior interfacial stability and therefore excellent catalytic performance. Excellent thermal stability is demonstrated under transmission electron microscopy with in situ heating up to 1023 K, as well as via long-term cycling (>370 hours) of a Li-O2 battery as a harsh electrochemical condition to challenge the catalyst stability. This work offers a new route toward constructing efficient and stable catalysts for various applications.

Ultrahigh-temperature melt printing of multi-principal element alloys.

Multi-principal element alloys (MPEA) demonstrate superior synergetic properties compared to single-element predominated traditional alloys. However, the rapid melting and uniform mixing of multi-elements for the fabrication of MPEA structural materials by metallic 3D printing is challenging as it is difficult to achieve both a high temperature and uniform temperature distribution in a sufficient heating source simultaneously. Herein, we report an ultrahigh-temperature melt printing method that can achieve rapid multi-elemental melting and uniform mixing for MPEA fabrication. In a typical fabrication process, multi-elemental metal powders are loaded into a high-temperature column zone that can be heated up to 3000 K via Joule heating, followed by melting on the order of milliseconds and mixing into homogenous alloys, which we attribute to the sufficiently uniform high-temperature heating zone. As proof-of-concept, we successfully fabricated single-phase bulk NiFeCrCo MPEA with uniform grain size. This ultrahigh-temperature rapid melt printing process provides excellent potential toward MPEA 3D printing.

Multi-principal elemental intermetallic nanoparticles synthesized via a disorder-to-order transition.

Nanoscale multi-principal element intermetallics (MPEIs) may provide a broad and tunable compositional space of active, high-surface area materials with potential applications such as catalysis and magnetics. However, MPEI nanoparticles are challenging to fabricate because of the tendency of the particles to grow/agglomerate or phase-separated during annealing. Here, we demonstrate a disorder-to-order phase transition approach that enables the synthesis of ultrasmall (4 to 5 nm) and stable MPEI nanoparticles (up to eight elements). We apply just 5 min of Joule heating to promote the phase transition of the nanoparticles into L10 intermetallic structure, which is then preserved by rapidly cooling. This disorder-to-order transition results in phase-stable nanoscale MPEIs with compositions (e.g., PtPdAuFeCoNiCuSn), which have not been previously attained by traditional synthetic methods. This synthesis strategy offers a new paradigm for developing previously unexplored MPEI nanoparticles by accessing a nanoscale-size regime and novel compositions with potentially broad applications.