Synthesis of ferrite and nickel ferrite nanoparticles using radio-frequency thermal plasma torch

Abstract

Nanocrystalline (NC) ferrite powders have been synthesized using a 50 kW–3 MHz rf thermal plasma torch for high-frequency soft magnet applications. A mixed powder of Ni and Fe (Ni:Fe=1:2), a NiFe permalloy powder with additional Fe powder (Ni:Fe=1:2), and a NiFe permalloy powder (Ni:Fe=1:1) were used as precursors for synthesis. Airflow into the reactor chamber was the source of oxygen for oxide formation. XRD patterns clearly show that the precursor powders were transformed into NC ferrite particles with an average particle size of 20–30 nm. SEM and TEM studies indicated that NC ferrite particles had well-defined polygonal growth forms with some exhibiting (111) faceting and many with truncated octahedral and truncated cubic shapes. The Ni content in the ferrite particles was observed to increase in going from mixed Ni and Fe to mixed permalloy and iron and finally to only permalloy starting precursor. The plasma-torch synthesized ferrite materials using exclusively the NiFe permalloy precursor had 40%–48% Ni content in the Ni-ferrite particle, differing from the NiFe2O4 ideal stoichiometry. EXAFS was used to probe the cation coordination in low Ni magnetite species. The coercivity and Neel temperature of the high Ni content ferrite sample were 58 Oe and ∼590 °C, respectively.