Synthesis of non-oxide materials includes solid-phase grinding, liquid building-up, plasma, and CVD. The raw powder of the sintered body is commercialized by solid-state synthesis; however, it is non-spherical in shape and its size is below the submicron range. In this synthesis, a prolonged heat treatment at high temperature, under a controlled atmosphere is indispensable. Such a treatment leads to a long grinding process in order to crush the heated aggregate powder. This results in the non-spherical shape of the resultant and leads to difficulties in synthesizing large-sized powder. Since the non-oxide materials have high intrinsic thermal conductivity, they have several potential uses apart from being used as sintered body, such as ceramic fillers. However, spherical powders above submicron levels are indispensable for this application. The ceramic filler powder is commonly produced by liquefied petroleum gas (LPG) firing. The advantages of this direct firing synthesis are high sphericity of product, high controllability of product size, rapid reaction rate (in seconds), productive and inexpensive continuous gas-phase flow reactor (non-batch processing). Despite these advantages, LPG firing has not been utilized in the synthesis of non-oxide materials by reactions in which oxygen has to be included as reactant.

In this study, we found that, conceptually, some Al nitridation syntheses via LPG firing could occur. The LPG firing method can provide a gas diffusion nitridation mechanism, and can therefore produce Al-oxynitride (AlON) and AlN spherical fine particles.

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