The effect of reactor temperature gradient on microstructures of sodium borosilicate glass powders produced by ultrasonic spray pyrolysis technique

Sodium borosilicate glass powders were produced by ultrasonic spray pyrolysis technique for three different reactor temperature gradients and the effect of the reactor temperature gradient on the microstructures of the powders produced was investigated. A three-zone ultrasonic spray pyrolysis system reactor in which the temperatures of each zone could be controlled separately was designed for this purpose. When the drying speed is high, early shell formation was observed in the aerosol droplets due to the difference of the drying speed between inner and outer parts and hollow powders were produced. In order to produce dense powder particles, shell formation on the aerosol droplet should be prevented, therefore drying speed should be decreased. The powders produced were glass-structured, spherical shaped and with smooth surfaces. The density of the hollow powder particle was 1.9 g/cm3 while the density of the dense particle was 2.5 g/cm3.