Combustion synthesis and engineering nanoparticles for electronic, structural and superconductor applications. Final report, May 31, 1992--May 30, 1996

Dense, nanocrystalline ceramic articles of doped ZrO{sub 2} (for use in solid electrolytes, oxygen sensors, electrode materials, thermal barrier coatings, etc.), BaTiO{sub 3} (for capacitor applications), and YBa{sub 2}Cu{sub 3}O{sub 7-x} (a high-temperature superconductor with uses, e.g., in magnetic flux trapping and high-speed capacitor applications) were prepared by the new nanofabrication process that has been developed in this research program. The process consists of two steps: synthesis of ceramic nanoparticles, and fabrication of dense ceramic articles that possess nanocrystalline features. The synthesis step is capable of producing 10-nanometer-diameter crystallites of doped ZrO{sub 2}, and of being scaled up to kilogram/hour production rates. The fabrication step produced dense, ultrafine-grained articles at significantly reduced sintering temperatures and times--representing a factor of 10-100 reduction in process energy requirements. The process has thus been shown to be technically feasible, while a preliminary engineering cost analysis of a pilot plant-scale version of the process indicates that it is both a cost- and an energy-efficient method of producing nanoparticles and nanocrystalline ceramics from those nanoparticles. One U.S. patent for this process has been allowed, and an additional five (continuation-in-part) applications have been filed. Technology transfer efforts have begun, through ongoing discussions with representatives from three manufacturing concerns