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Volume 111
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Synergetic preparation of flaky α-Al2O3 with large particle size and high aspect ratio via seed-induced epitaxial growth and calcination strategy
Gaohui Liu a, Yaqi Guo a, Jianguo Zhao b, Songquan Chen a, Hongyu Liu a, Xiujing Peng a, Yu Cui a, Xuchuan Jiang a *, Guoxin Sun a *
a Institute for Smart Materials & Engineering, School of Materials Science and Engineering, University of Jinan, Jinan, 250022, China
b Dezhou Hongruijia Chemical Technology Co., Ltd., Dezhou, 251200, China
10.1016/j.partic.2026.02.008
Volume 111, April 2026, Pages 223-230
Received 18 November 2025, Revised 12 January 2026, Accepted 6 February 2026, Available online 12 February 2026, Version of Record 7 March 2026.
E-mail: ism_jiangxc@ujn.edu.cn; chm_sungx@ujn.edu.cn
Highlights

• Prepare flake α-Al2O3 by combining sol-gel and molten salt methods.

• Prepare flake α-Al2O3 seed crystals with well-defined morphology.

• Prepare large particle size flake α-Al2O3 by introducing seeds.

• Tackle crystal breakage by controlling cooling rate in late calcination stage.


Abstract

A synergistic strategy was established for the controllable synthesis of flaky α-Al2O3 by integrating the sol-gel method, molten salt method, seed-induced epitaxial growth, and optimized calcination. α-Al2O3 seeds with a diameter of approximately 8 μm and a regular hexagonal shape were introduced to direct crystal growth. Programmed cooling from 1100 to 900 °C over 120 min, followed by further cooling to 600 °C over 90 min, was applied to relieve thermal stress and promote ordered crystallization. The resulting flaky α-Al2O3 exhibited an average particle size of 49.28 μm, a thickness of 600 nm, and an aspect ratio of 82. This method not only doubled the particle size but also maintained a high degree of regularity in crystal morphology, providing a novel material solution with large particle size and excellent shape for applications such as ceramic reinforcement materials, thermal-conductive fillers, and pearlescent pigments.

Graphical abstract
Keywords
Flake α-Al2O3; Sol-gel method; Molten-salt method; Seeds; Calcination process
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