The major advances in the field of the designed construction of hierarchically structured porous inorganic or hybrid materials wherein multiscale texturation is obtained via the combination of aerosol or spray processing with sol-gel chemistry, self-assembly and multiple templating are the topic of this review. The available materials span a very large set of structures and chemical compositions (silicates, aluminates, transition metal oxides, nanocomposites including metallic or chalcogenides nanoparticles, hybrid organic-inorganic, biohybrids). The resulting materials are manifested as powders or smart coatings via aerosol-directed writing combine the intrinsic physical and chemical properties of the inorganic or hybrid matrices with defined multiscale porous networks having a tunable pore size and connectivity, high surface area and accessibility. Indeed the combination of soft chemical routes and spray processing provides "a wind of change" in the field of "advanced materials". These strategies give birth to a promising family of innovative materials with many actual and future potential applications in various domains such as catalysis, sensing, photonic and microelectronic devices, nano-ionics and energy, functional coatings, biomaterials, multifunctional therapeutic carriers, and microfluidics, among others.

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Despite the widespread use of amorphous aluminosilicates (ASA) in various industrial catalysts, the nature of the interface between silica and alumina and the atomic structure of the catalytically active sites are still subject to debate. Here, by the use of dynamic nuclear polarization surface enhanced NMR spectroscopy (DNP SENS) and density functional theory (DFT) calculations, we show that on silica and alumina surfaces, molecular aluminum and silicon precursors are, respectively, preferentially grafted on sites that enable the formation of Al(IV) and Si(IV) interfacial sites. We also link the genesis of Brønsted acidity to the surface coverage of aluminum and silicon on silica and alumina, respectively.

Brønsted acid sites of similar strength to those in zeolites are found in ASAs prepared by cogelation, as shown by thermogravimetric study of the dehydration of ethanol to ethylene. ASAs prepared by grafting and a commercial ASA (Siralox 30) show Brønsted acid sites that differ from those of zeolites. CO respectively ethanol adsorption followed by infrared spectroscopy identified the OH stretching frequency of the Brønsted acid sites specific to Si/Al 2 O 3 and Al/SiO 2 materials obtained by grafting to be ca. 3600 cm-1 and 3640 cm-1 , respectively, although the intensity of the corresponding band is weak. These sites, contrary to those of a H-USY zeolite with very few extraframework aluminium, are highly sensitive to the surface hydration state: Their number decreases with increasing temperature. The surface structure of Siralox 30 resembles that of Si/Al 2 O 3 prepared in anhydrous conditions, showing similar isosurface acidic properties and distribution of silicon species.

Aerosol processing is long known and implemented industrially to obtain various types of divided materials and nanomaterials. The atomisation of a liquid solution or suspension produces a mist of aerosol droplets which can then be transformed via a diversity of processes including spray-drying, spray pyrolysis, flame spray pyrolysis, thermal decomposition, micronisation, gas atomisation, etc. The attractive technical features of these aerosol processes make them highly interesting for the continuous, large scale, and tailored production of heterogeneous catalysts. Indeed, during aerosol processing, each liquid droplet undergoes well-controlled physical and chemical transformations, allowing for example to dry and aggregate pre-existing solid particles or to synthesise new micro- or nanoparticles from mixtures of molecular or colloidal precursors. In the last two decades, more advanced reactive aerosol processes have emerged as innovative means to synthesise tailored-made nanomaterials with tunable surface properties, textures, compositions, etc. In particular, the "aerosol-assisted sol-gel" process (AASG) has demonstrated tremendous potential for the preparation of high-performance heterogeneous catalysts. The method is mainly based on the low-cost, scalable, and environmentally benign sol-gel chemistry process, often coupled with the evaporation-induced self-assembly (EISA) concept. It allows producing micronic or submicronic, inorganic or hybrid organic-inorganic particles bearing tuneable and calibrated porous structures at different scales. In addition, pre-formed nanoparticles can be easily incorporated or formed in a "one-pot" bottom-up approach within the porous inorganic or hybrid spheres produced by such spray drying method. Thus, multifunctional catalysts with tailored catalytic activities can be prepared in a relatively simple way. This account is an overview of aerosol processed heterogeneous catalysts which demonstrated interesting performance in various relevant chemical reactions like isomerisation, hydrogenation, olefin metathesis, pollutant total oxidation, selective oxidation, CO2 methanation, etc. A short survey of patents and industrial applications is also presented. Our objective is to demonstrate the tremendous possibilities offered by the coupling between bottom up synthesis routes and these aerosol processing technologies which will most probably represent a major route of innovation in the mushrooming field of catalyst preparation research.

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The number and types of acid sites and the catalytic activity of amorphous silica–alumina, obtained by grafting silicon species to the surface of γ‐alumina, varies with the synthesis conditions and the amount of grafted silicon. IR spectroscopy of the OH region proves that deposition occurs selectively, first on the (1 0 0) and then on the (1 1 0) facets. Grafting onto the (1 0 0) surface lowers the number of active sites in ethanol dehydration. Grafting onto the (1 1 0) surface yields Brønsted acid sites that are active in the dehydration of ethanol and that catalyze the isomerization of m‐xylene. Strong Lewis acid sites, or “defect sites”, as detected by CO adsorption, also appear, although they are absent on the parent alumina. The stoichiometric dehydration of ethanol on Brønsted sites, monitored by using thermogravimetric analysis, enables the calculation of the turnover frequency of these sites in m‐xylene isomerization (1.4×10−3 s−1 site−1 at 350 °C, atmospheric pressure, 0.6 cm3 h−1 of m‐xylene, and 0.5 g of catalyst). This number is 22 times lower than on a USY zeolite without extraframework aluminum.

An old dream comes true: A direct and environmentally benign synthetic strategy was developed for the aerosol-based mass production of large-pore mesostructured aluminosilicate powders (see TEM image). Although amorphous, some powders exhibit higher activity towards m-xylene isomerization and lower coke formation than a Y-zeolite based industrial reference catalyst.