Electrified vapour deposition at ultrahigh temperature and atmospheric pressure for nanomaterials synthesis

Wang, Xizheng; Liu, Ning; Huang, Zhennan; Yang, Ji; Chen, Gang; Li, Boyang; Xie, Ti; Overa, Sean; Brozena, Alexandra H; Li, Tangyuan; Mumtaz, Farhan; Zhang, Bohong; Lin, Ying; Li, Mingze; Mei, Bowen; Li, Shuke; Huang, Jinsong; Huang, Jie; Jiao, Feng; Gong, Cheng; Wang, Guofeng; Chi, Miaofang; Takeuchi, Ichiro; Ju, Yiguang; Hu, Liangbing

doi:10.1038/s44160-025-00914-4

Title: Electrified vapour deposition at ultrahigh temperature and atmospheric pressure for nanomaterials synthesis

Journal Article · Wed Nov 05 00:00:00 UTC 2025 · Nature Synthesis

DOI: https://doi.org/10.1038/s44160-025-00914-4 · OSTI ID:3004737

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Univ. of Maryland, College Park, MD (United States); Univ. of California, Irvine, CA (United States)
Princeton Univ., NJ (United States)
Univ. of Maryland, College Park, MD (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Univ. of Maryland, College Park, MD (United States); Yale Univ., New Haven, CT (United States)
Univ. of Maryland, College Park, MD (United States)
Univ. of Pittsburgh, PA (United States)
Univ. of Delaware, Newark, DE (United States)
Missouri Univ. of Science and Technology, Rolla, MO (United States)
University of North Carolina, Chapel Hill, NC (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Washington Univ., St. Louis, MO (United States)
Princeton Plasma Physics Laboratory (PPPL), Princeton, NJ (United States); Princeton Univ., NJ (United States)

Vapour-phase synthesis methods have shown promise for the scalable synthesis of nanomaterials and coatings. However, the vaporization of different precursors for the synthesis of a broad nanomaterial space, particularly at atmospheric pressure, while maintaining compositional and structural control of the final product is challenging. Here we report the generation of an ultrahigh-temperature atomic vapour at atmospheric pressure based on electrified heating, for the growth of multi-elemental nanomaterials and thin films. This process relies on a reactor design whereby solid-state precursors are vaporized within a semi-confined space beneath an electrified heater that can reach ~3,000 K. The proximity of the heater rapidly breaks down the bonds of metal salt precursors and decomposes them into an atomic vapour that expands into a high-temperature (>2,000 K), highly reactive and high-flux vapour (10²¹–10²² atoms per cm² per second) that travels upwards in a directional flow. When mixed with entrained ambient gases, the highly reactive atomic species rapidly nucleate and grow into the desired final products, including alloys, oxides, sulfides and thin films, which can be deposited on a low-temperature substrate. This EVD approach can synthesize a broad range of functional nanomaterials at atmospheric pressure, including single-phase multi-elemental nanomaterials formed under thermodynamically non-equilibrium conditions.

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Research Organization:: Princeton Plasma Physics Laboratory (PPPL), Princeton, NJ (United States); Princeton Univ., NJ (United States)

Sponsoring Organization:: National Science Foundation (NSF); USDOE Advanced Research Projects Agency - Energy (ARPA-E); USDOE Office of Science (SC), Basic Energy Sciences (BES). Chemical Sciences, Geosciences & Biosciences Division (CSGB); USDOE Office of Science (SC), Basic Energy Sciences (BES). Materials Sciences & Engineering Division (MSE); USDOE Office of Science (SC), Fusion Energy Sciences (FES)

Grant/Contract Number:: AR0001922; SC0020233; SC0021135; SC0025281; SC0025371

OSTI ID:: 3004737

Journal Information:: Nature Synthesis, Journal Name: Nature Synthesis Journal Issue: 1 Vol. 5; ISSN 2731-0582

Publisher:: Springer NatureCopyright Statement

Country of Publication:: United States

Language:: English

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