Molten salt synthesis (MSS) of complex
oxides is generally investigated
by characterization of the product phases with no insight into evolution
of particle morphology. In this work, LaFeO3 and LaMnO3 MSS was investigated in KF–KCl and LiCl–KCl
at 850 °C using a “feeding-and-sampling” procedure.
By feeding the oxide reagents into a molten salt, the reaction starting
point was clearly defined, while subsequent sampling of the melt provided
means for tracking the phase composition along with the shape and
size of product particles during MSS. Samples taken just after 1 min
contained perovskite particles along with reagents and intermediates,
which were consumed over time to yield a pure product within 10–30
min. The shape and size of perovskite particles sampled at different
times during MSS were virtually unchanged, revealing a lack of notable
growth. The observed fast MSS along with prevailing nucleation provided
means to control perovskite particle size by varying the extent of
reagent dissolution. Thus, increasing the salt/reagent ratio (from
10:1 to 25:1) strikingly reduced the duration required to obtain a
pure product, along with decreasing the size of product particles
(from 0.5–1.5 μm to 80–200 nm). Furthermore, performing
MSS in KF–KCl, which exhibits greater oxide solubility compared
to LiCl–KCl, resulted in a shorter duration and smaller perovskite
particles (80–200 nm and 0.6–2.0 μm, respectively).
This insight into perovskite formation and growth during MSS and its
kinetics provides valuable guidelines for tuning MSS conditions to
better control synthesis duration and particle size.