Abstract
Flame spray pyrolysis of precursor-solvent combinations with high enthalpy density allows the design of functional nanoscale materials. Within the last two decades, flame spray pyrolysis was utilized to produce more than 500 metal oxide particulate materials for R&D and commercial applications. In this short review, the particle formation mechanism is described based on the micro-explosions observed in single droplet experiments for various precursor-solvent combinations. While layer fabrication is a key to successful industrial applications toward gas sensors, catalysis, and energy storage, the state-of-the-art technology of innovative in situ thermophoretic particle production and deposition technology is described. In addition, noble metal stabilized oxide matrices with tight chemical contact catalyze surface reactions for enhanced catalytic performance. The metal-support interaction that is vital for redox catalytic performance for various surface reactions is presented.