Conference Agenda

As technology advances, the demand for compact, high-efficiency electronic devices grows, especially those with power converters like powder core inductors (PCIs). FeNi-based materials are ideal for PCIs due to their high permeability and low coercivity. This study focuses on the aerosol synthesis of dense FeNi particles and silica-coated FeNi (FeNi@SiO₂) particles, using a swirler connector-assisted spray pyrolysis method. The tuned process controls particle quality, minimizes carbon impurities, and determined silica coating. Results show that low impurities, and uniform silica shells are essential for improving PCI performance, efficiency, and stability, particularly regarding DC bias, core loss, and breakdown voltage.

In this study, we explore a combustion-aerosol process designed to systematically capture a high-temperature phase and stabilize it at room temperature, as demonstrated with CoCu₂O₃. Using a combination of ex situ and in situ X-ray diffraction, electron microscopy, and real-time flame characterization, we investigate the synthesis and thermal stability of CoCu₂O₃ nanocrystals, along with the formation of thermodynamically stable phases and cluster structures. This work establishes general thermodynamic-process relationships to regulate phase composition as a function of flame-aerosol engineering parameters, including precursor concentration, temperature profile, and high-temperature residence time.

The rising threat of air pollution has accelerated advancements in gas-sensing technologies, particularly those utilizing carbon-based materials like activated carbons (ACs). This study explores an innovative approach to fabricating noble metal-carbonaceous films from recycled e-waste for next-generation gas sensors. Noble metals are selectively recovered via hydrometallurgical leaching and adsorbed onto AC substrates. Using electrospray deposition, these metal-loaded ACs form thin films with tunable morphology and surface properties. The resulting films are evaluated for sensing applications, emphasizing sustainability and circular economy principles. This research bridges nanomaterial fabrication with eco-friendly resource recovery, enhancing sensor performance while minimizing environmental impact.

Mixed catalysts are scarcely used because of the present a lack of scalable synthesis methods. Catalysts based on atomic clusters are presently not used because of their strong mobility on surfaces. Very recently introduced flexible aerosol synthesis principles for (mixed) nanoparticulate and atomic cluster catalysts are reviewed. Spark ablation plus Artificial Intelligence, DFT, XRD and XPS correctly predict the composition of improved catalysts. A heteroatom doped carbonaceous support enables very stable immobilization of the atomic clusters. Ag atoms stabilize Cu atomic clusters. The Cu-Ag atomic clusters on the carbonaceous layer exhibit electrochemical conversion of CO2 to acetaldehyde with 92% selectivity.

Surface enhanced Raman spectroscopy (SERS) is a highly specific spectroscopic technique, which utilizes the plasmonic enhancement provided by metallic nanostructures. Such SERS substrates can be produced by depositing nanoparticles produced during spark ablation to a filter. The properties of the substrate can be adjusted through the parameters of the fabrication method, such as the frequency of the sparking, the temperature of the particle compaction, or the type of filter used. We investigated the effects these parameters have on the SERS enhancement and also applied the optimal substrate in thiram sensing, where 1.2 ppm thiram was found to be directly detectable.

I present an overview of flame aerosol deposition (FAD) as a scalable technique for fabricating functional nanostructured films with tailored properties. In biosensing, FAD enables the creation of highly porous films that enhance sensor sensitivity, supporting plasmonic sensing via surface-enhanced Raman scattering or colorimetric detection. Additionally, tunable plasmonic films extend photothermal responses for surface disinfection and microneedle fabrication. In biomedical applications, FAD-derived antibacterial and antifouling coatings prevent bacterial adhesion, while photocatalytic films achieve visible-light disinfection. These advances highlight FAD’s potential for next-generation biomedical coatings, with future research focusing on improved deposition strategies and functionalization approaches.