Synthesis of metallic alloy particles on flat graphitic interfaces in arc discharge

The application of arc discharge to synthesising encapsulated (Fe-Cu-Al)@C structures is studied. The cost-effectiveness of the proposed technique may be beneficial for developing a new method for large-scale production of metal micro- and nanoparticles protected from oxidation by a carbon shell.A copper sample was immersed into a mixture of graphite, iron, and aluminium powder and placed into a negatively powered crucible of a setup designed to ignite arc discharge at atmospheric conditions. The proposed approach prevents the oxidation of droplets of Fe-Cu-Al alloy by covering them with a thin layer of carbon, which is also engaged as a collector of the metal particles.The application of arc discharge resulted in the generation of metal particles and various carbon nanostructures, which were confirmed by SEM images. The nanostructures were grouped into more complex flower-, ball-, tree-, and octopus-shaped structures with a large yield of metallic alloy particles ranging from a few μm (micrometers) to nanometre sizes. These findings suggest the catalytic application of the structures after the grown particles are cleared from the carbon shell to be implemented as active chemical agents.The main limitation is the uncontrolled heat transfer from the discharge volume. Therefore, an additional screen should be installed around the volume in order to improve control over synthesis in future studies.This research confirms a flexible and simple method of synthesising metallic alloy particles that may be applied for catalytic applications.The synthesis is conducted using a well-known arc discharge technique to expand the production yield and diversity of chemically-active metal particles protected from oxidation by a shell before the intended application.