Simone Vinati1, Alessandro Antonini1, Paolo Piseri1, Paolo Milani1, Luca Belforte2, Nello Li Pira2, and Karsten Wegner3. (1) Tethis S.r.l., Via Russoli, 3, I-20143 Milan, Italy, (2) Advanced Manufacturing & Materials, Centro Ricerche Fiat, Strada Torino, 50, I-10043 Orbassano, Italy, (3) Swiss Federal Institute of Technology (ETH), Sonneggstrasse 3, CH-8092 Zurich, Switzerland
A novel one-step deposition method for nanostructured coatings combining gas-phase flame synthesis of nanoparticles and supersonic cluster beam deposition is presented. Metal-oxide and noble metal nanoparticles are first produced by high temperature flame spray pyrolysis. The combustion aerosol is then expanded through a critical flow nozzle into the first vacuum chamber of the deposition unit. Thereby, the aerosol is rapidly quenched freezing nanoparticle growth. A series of aerodynamic lenses in the vacuum deposition apparatus filters out large particles and focuses the remaining aerosol into a beam. The particle beam is then directed at a substrate generating porous nanoparticulate films, for application in catalysis, gas sensing, or biotechnology.