Spray flame synthesis of Y2O3-MgO nanoparticles for mid-infrared transparent nanocomposite ceramics

Spray flame synthesis offers a promising method for scalable production of homogeneously mixed Y2O3-MgO nanopowders as next-generation infrared-transparent window material, which has attracted significant attention owing to its excellent optical properties at high temperatures. However, systematic understanding of how flame synthesis parameters influence particle morphology, crystal phase, solid solubility, and subsequent ceramic performance remains insufficiently understood. In this study, we investigated the influence of precursor chemistry on particle crystal phase and examined the solid solubility of MgO in Y2O3 under different flame temperatures, demonstrating that the high-temperature conditions with O2 as dispersion gas allow up to 50 mol% MgO to fully dissolve into Y2O3, far exceeding the equilibrium solubility limit of 7 mol% at the eutectic temperature (2100°C) and near-zero at room temperature. Furthermore, we systematically evaluated how powder characteristics and sintering parameters-including powder deagglomeration methods, vacuum sintering temperature, hot isostatic pressing (HIP) temperature, and initial powder characteristics-affect ceramic microstructures and infrared transmittance. Despite cracking induced by phase transformation and finer particle sizes, ceramics fabricated from oxygen-synthesized monoclinic-dominated powders exhibited superior near-infrared transmittance (56.2% at 1550 nm), attributed to enhanced atomic mixing and effective grain boundary pinning. After optimization, pure cubic phase powders produced intact and crack-free ceramics with outstanding mid-infrared transparency, achieving a maximum transmittance of 84.6% and an average transmittance of 82.3% in 3-5 um range.