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Spray Pyrolysis

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lightbulbAbout this topic
Spray pyrolysis is a chemical deposition technique used to produce thin films and nanoparticles by atomizing a precursor solution into fine droplets, which are then subjected to high temperatures. This process facilitates the thermal decomposition of the precursors, resulting in the formation of solid materials with controlled composition and morphology.
lightbulbAbout this topic
Spray pyrolysis is a chemical deposition technique used to produce thin films and nanoparticles by atomizing a precursor solution into fine droplets, which are then subjected to high temperatures. This process facilitates the thermal decomposition of the precursors, resulting in the formation of solid materials with controlled composition and morphology.

Key research themes

1. How can process parameters and mathematical modeling optimize Spray Pyrolysis thin film deposition for tailored material properties?

This research theme centers on the empirical and computational investigation of Spray Pyrolysis Technique (SPT) to control thin film deposition, particularly of metal oxides. Understanding how process variables such as substrate temperature, precursor concentration, and solution composition influence film morphology, microstructure, and compositional homogeneity is crucial for fabricating films with desired functional properties in sensors, optoelectronics, and photovoltaics. Mathematical modeling that couples atomization, evaporation, chemical reaction, and deposition phases enhances the ability to predict and tailor film thickness and particle size distribution, thereby supporting process optimization and scale-up.

Key finding: Developed a comprehensive model—incorporating atomization, spray, evaporation, chemical reaction, and deposition—accurately predicting particle size distribution and film thickness under high temperatures consistent with... Read more
Key finding: Systematic study showing substrate temperature as a dominant parameter controlling crystal growth, film homogeneity, and composition for ZnO, SnO2, and their indium-doped mixed oxides. Films produced at substrate temperatures... Read more
Key finding: Reviewed emerging challenges and innovations in thermal spray processes, including cold spray and spray pyrolysis derivatives, emphasizing the need for integrated modeling and experimental validation. Highlighted that process... Read more

2. What are the underlying physicochemical mechanisms shaping nanoparticle formation during Flame Spray Pyrolysis and their control strategies?

This theme focuses on the gas-phase chemical and physical processes governing nanoparticle synthesis by Flame Spray Pyrolysis (FSP). Research investigates the precursor decomposition, droplet combustion dynamics (including micro-explosions), and particle nucleation pathways affecting particle size, morphology, and phase. The interplay between gas-to-particle and droplet-to-particle conversion routes is particularly critical. Understanding these mechanisms is foundational for engineering multifunctional nanostructures and optimizing reactor designs for scale-up and integration into nanodevice fabrication.

Key finding: Using single droplet combustion as an analog to FSP, this study elucidates heterogeneous vapor-phase nucleation mechanisms under thermal decomposition leading to micro-explosions, which enhance homogeneous nanoparticle... Read more
Key finding: Provides a state-of-the-art overview of FSP reactor designs and process modifications, such as double-nozzle configurations and oxygen-deficient flames, enabling precise control over nanoparticle morphology and phase... Read more
Key finding: Experimental characterization of spray flame dynamics in fuel-rich and MILD (Moderate and Intense Low oxygen Dilution) combustion regimes revealed that hot-diluted oxidant coflows drastically alter atomization and flame front... Read more

3. How do fuel chemistry and endothermic pyrolysis reactions influence spray ignition and particle vaporization in thermal spray and combustion processes?

This theme addresses the chemical kinetics of endothermic pyrolysis reactions during spray ignition and high-temperature vaporization, impacting ignition delay, flame stabilization, particle vaporization rates, and the formation of undesirable byproducts like soot. Studies analyze the role of fuel molecular structure, precursor volatility, and spray parameters on ignition and vaporization, underlining the importance of coupling physical spray characteristics with detailed chemical kinetic modeling. These insights are crucial for designing thermal spray processes and combustion systems with improved efficiency and lower emissions.

Key finding: Identified that endothermic pyrolysis of diesel fuels during initial spray injection leads to an observable pressure decrease before ignition, altering traditional physical-chemical ignition delay demarcations. Demonstrated... Read more
Key finding: Revealed that alkanes exhibit significantly slower vaporization rates than predicted by classical evaporation models due to endothermic fuel pyrolysis consuming heat and forming soot. Developed an analytical model using... Read more
Key finding: Demonstrated that pyrolysis gases from wheat starch significantly modify ignition energy requirements and explosivity parameters of dust clouds. Experimental quantification showed that presence of low-percentage pyrolysis... Read more

All papers in Spray Pyrolysis

This review explores the mechanisms of spray pyrolysis for cadmium telluride (CdTe) thin-film photocathodes, focusing on droplet dynamics, nucleation processes, and film formation pathways relevant to photovoltaic and photocathode... more
In this study doped SnO 2 thin films have been prepared by spray pyrolysis technique using an alcoholic precursor solution consisting of stannic chloride (SnCl 4 .5H 2 O), ammonium fluoride (NH 4 F) and palladium chloride (PdCl 2 ).... more
Pd-F:SnO 2 thin films have been prepared by spray pyrolysis technique using an alcoholic precursor solution consisting of stannic chloride (SnCl 4 .5H 2 0), ammonium fluoride (NH 4 F) and palladium chloride (PdCl 2 ). Optimization on the... more
We present a fully variational and strictly rigorous derivation of Hawking radiation within the framework of Vortex Field Theory (Dziabura, 2025). Starting from a microscopic action containing the vortex tensor ω_{μν}, the comoving... more
Mossbauer effect studies of NiFe,O, were carried out in the temperature range from 300 up to 800 K. The analysis of the ME spectra gave the values of Debye temperature, the recoil free fraction, the mean square displacement, and velocity... more
In this paper, thin films of copper oxide nanoparticles mixed with 2% wt of nickel oxide are deposited on glass and porous silicon (PS) substrates with orientation (111) etched at 30 minutes. The current density was varied from (10 to 50)... more
The deposition of a thin tin oxide film allows for the manufacture of modern gas sensors. Spray pyrolysis deposition is used to grow the required thin films, as it can be seamlessly integrated into a standard CMOS processing sequence. A... more
Gas sensors are based on metal oxides, which likely will have a considerable impact on future smart phones, are analyzed by means of simulations. The deposition of a thin tin oxide film at the backend of a CMOS process has enabled the... more
Integration of thin tin oxide film formation into CMOS technology is a fundamental step to realize sensitive smart gas sensor devices. Spray pyrolysis is a deposition technique which has the potential to fulfil this requirement. A model... more
Preparation of highly conducting and transparent cadmium tin oxide () 4 2SnO Cd thin films by vacuum evaporation technique on glass substrate with thickness of (300, 600)nm is reported. The effect of thickness on structural, optical, and... more
Solar cells based on organic dye have been widely used for the reason of their simplicity of manufacture. A simple structure is composed of a colored layer of TiO2, an electrolyte and a counter electrode. In this study, the layers of... more
Metal oxide semiconductors are one of the most promising materials for photoelectrochemical production of hydrogen on account of a) easy availability, b) low cost, c) simple preparation methods and d) stability. The samples of undoped and... more
The photoelectrochcmical properties o f copper oxide thiii film (p4ypc) on the SnO, F coated glass (conducting glass) picparcd by spray pyrolysis has been investigated as a (unction dopant and pH o( electrolyic ?<-iay difliactogiain... more
Synthesis of advanced ceramic materials with improved microstructure, finding widespread applications as photocatalysts, is a challenge before the chemists. This communication describes a wet chemical method based upon sol-gel technique,... more
Thin films of ZnO, ZnO:Cu, ZnO:N and ZnO:(Cu,N) have been deposited on glass substrate at temperature 350ºC by low cost spray pyrolysis (SP) technique at an ambient atmosphere. The X-ray diffraction (XRD) study revealed that the films are... more
Perovskite oxides are receiving wide interest for photocatalytic and photoelectrochemical devices, owing to their suitable band gaps for solar light absorption and stability in aqueous applications. Herein, we assess the activity of... more
Cr-doped titanite (CaTiSiO 5 ) pigments were synthesized through spray pyrolysis of aerosols generated from aqueous solutions containing colloidal silica, calcium chloride, titanium(IV) oxychloride and chromium(III) nitrate. This process... more
For the first time copper gallium sulphide (CuGaS2) films were prepared using the brush plating method at various electrolyte temperatures between 30 and 80 degrees Celsius with a steady current density of 5.0mA cm-2 CuGaS2 photo... more
Different thin films samples made of SnO 2 , F:SnO 2 , Pd: SnO 2 and and co-doped Pd-F: SnO 2 were deposited at a substrate temperature of 450 o C using optimized doping concentrations of F and Pd, thereafter the samples were annealed and... more
In this report, we have prepared undoped and Mg-doped ZnO thin films by a modified successive ionic layer adsorption and reaction (SILAR) method. The structural, surface morphological, chemical compositional, and optical properties of... more
The single cells were characterized with respect to performance and long term behavior (&gt; 1000 h) including load and thermal cycling. As can be seen in Fig. 3, current densities of 0.18 A/cm (750°C), 0.43 A/cm (850°C) and 0.7 A/cm... more
The main objectives of H. C. Starck's internal development program for powders used in SOFC applications are to meet the cost targets of the customers as well as the performance requirements during cell operation. Optimization of... more
Abstract- Crystallites of ZnO and Zn0.99Co0.01O have been grown on glass substrate by wet chemical decomposition of zinc/cobalt-amino complexes in aqueous medium. Structural properties of grown crystallites were investigated by the help... more
Semiconductors are solids with crystalline structures. In solids, electron orbitals overlap and creating energy bands due to atomic bonds / overlap. In the solid state, electrons do not remain permanently bound to an atom; they constantly... more
Structural studies on In 2 S 3 thin films deposited by vacuum thermal evaporation on glass substrates at a temperature of 240 o C, followed by annealing at 330°C and 400°C are presented. It was shown that the films were of amorphous in... more
In this work, we have carried out a comparative research of the nanoscale modification of the surface morphology of polycrystalline SnS films on glass substrates with two different preferred growth orientations during sputtering in... more
Films of pure tin oxide SnO2 and in presence of antimony atoms (SnO2-Sb) deposited onto glass substrates have shown a sufficiently high energy gap to be transparent in the visible region, a high electrical mobility and a carrier... more
The flame spray pyrolysis (FSP) synthesis of silica particles from two different precursors, tetraethylorthosilicate (TEOS) and silicic acid which have significantly different volatilities, was investigated. The size and morphology of the... more
ZnO lms were deposited on glass substrates by ultrasonic spray pyrolysis technique at a substrate temperature of 300 ± 5 • C. All of the lms have been annealed at 500 • C temperature for dierent time (1, 2, and 3 h) to improve the... more
The structural and room temperature luminescent characteristics of rare earth doped yttrium-aluminum oxide films deposited by the spray pyrolysis technique at low temperatures have been studied as a function of the deposition parameters... more
Nanostructured copper oxide (CuO) thin films have been synthesized onto the glass substrates from aqueous solutions of copper (II) acetate monohydrate precursor salt by a cost effective spray pyrolysis technique at various substrate... more
Undoped and manganese (Mn)-doped zinc oxide (ZnO) thin films have been deposited onto glass substrates at 300 • C using a low cost spray pyrolysis technique. Structural, optical and electrical properties of the as-deposited films have... more
Pure and magnesium (Mg) doped zinc oxide (ZnO) thin films were prepared onto clean glass substrate by spray pyrolysis (SP) technique at the substrate temperature of 300°C. Various optical parameters such as absorption co-efficient, band... more
High-energy spectroscopy has been used to study the electronic structure and valence state of new ternary intermetallic CeM2P2 (M=Fe, Co, Ni) compounds which crystallize in the ThCr2Si2 types. The calculations of electron energy bands... more
The valence band electronic structure of compounds with the HfFe2S2 crystal lattice type has been established for the first time based on X-ray emission spectroscopy measurements. Band structure and theoretical spectra of X-ray emission... more
Very simple and low-cost raw material was used to prepare Al2O3 nano-thin films Only Al(No3)3-9H2O and 2-methoxy ethanol were used to prepare the required thin films employing spray pyrolysis method at low substrate temperature. The FTIR... more
Titanium dioxide (TiO2) nanoparticles containing iron, silicon, and vanadium are synthesized using multiple diffusion flames. The growth of carbon-coated (C-TiO2), carbon-coated with iron oxide (Fe/C-TiO2), silica-coated (Si-TiO2) and... more
In this work we present some results of a systematical study of structural and optoelectronic properties of Zn O:In thin films obtained by spray pyrolysis when the acidity and the solvent used in starting solution were varied. Structure... more
The results of a systematic study of the electrical. optical. structural and surface properties ofthin ZnO:ln films are presented. The films were deposited by the spray pyrolysis technique. The spraying solution was zinc acetate diluted... more
Gallium, aluminum, and indium-doped ZnO (ZnO:Ga, ZnO:Al, and ZnO:In) films have been deposited by the chemical spray method on sodocalcic substrates. The effect of different dopant elements, a post-annealing treatment in vacuum, and the... more
Indium doped zinc oxide (ZnO:In) thin solid films were deposited on soda-lime glass substrates by the ultrasonic spray pyrolysis technique. The effect of the substrate temperature on the electrical, morphology, and optical characteristics... more
PEDOT/PMVP coated pores inside a track-etch membrane can occur not withstanding the fact that the active site of the enzyme is hidden deeply inside the insulating protein shell. Further research is ongoing to elucidate this intriguing... more
Pure and doping with Zn material on CeO 2 films were formed on the substrate at 250 °C and further it was annealing at 350 °C in the atmosphere for 2 h using spray pyrolysis technique. Noticeable variation in the crystallite size,... more
Effect of annealing temperature on the properties of CdS thin films are carried out in this work. Nanocrystalline cadmium sulphide (CdS) thin films were prepared using spray pyrolysis deposition (SPD) technique and the structural, optical... more
Abstract: An asymmetrical factorial experiment approach was used for improved gas/odor discrimination using thick film gas sensor data. The results revealed that the gases/odors(G), sensors(S), concentrations of gases(C), and interactions... more
The focus of this study was to develop a method to demonstrate the feasibility of obtaining useful and high-value resources from Phoenix dactylifera residues and, to determine the physical and chemical properties of the ash of... more
The effect of 170 MeV Au 13þ irradiation on photoelectrochemical (PEC) and structural properties of CuO thin films has been investigated. The X-ray diffractograms of post-irradiated CuO thin films showed diffused nature towards higher... more
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