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The ability to reproduce the synthesis of dense- and porous-microspheres and micron-sized spherical shells is very important in (a) the development of ceramics for structural, electronic, catalyst and thermal applications; and (b) the encapsulation of products for controlled-release of drugs, flavors and perfumes, and inks and dyes, and the protection of light-sensitive components and mechanical support of fragile materials. Larger metallic- and ceramic-spherical shells have been used in inertial confinement fusion (ICF) experiments and as catalyst supports. The current paper will focus on a recent technique that has been developed for synthesizing ceramic microspheres and micro-shells. Pulsed electric fields have been used to enhance the dispersion of aqueous metal (Zr and Al) salt solutions from a nozzle and into a nonconducting liquid continuous phase that is immiscible with the aqueous phase. The diameter of the resulting microdroplets ranged in size from approximately 0.1 to 10 {mu}m. Precipitation of hydrous metal oxides occurred as ammonia, which was dissolved in varying amounts in the continuous phase, diffused into the aqueous microdroplets. Spherical shells were formed at higher ammonia concentrations and microspheres were produced at lower ammonia concentrations. Upon drying, dimples appeared in the particles that were synthesized at higher ammonia concentrations. The latter result accords with the well known fact that under certain conditions spherical shells collapse when a fluid is extracted from the core of the particle. No dimples were observed in the microspheres that were produced at lower ammonia concentrations. Analog X-ray dot maps for aluminum and zirconium were done to determine the spatial distribution of each metal in the particles

Porous spherical shells and microspheres by electrodispersion precipitation