Nanoparticles of pure metals, oxides, carbides, and nitrides, can be created by vaporizing a solid precursor with a thermal plasma and then condensing the vapor by expansion or quenching in a suitable gas or liquid. The plasma can be produced by dc jet, electric arc, or radio frequency (RF) induction. The thermal plasma can reach temperatures of 10.000 K and can thus also synthesize nanopowders with very high boiling points. Metal wires can be vaporized by the exploding wire method.
In RF induction plasma torches, energy coupling to the plasma is accomplished through the electromagnetic field generated by the induction coil. The plasma gas does not come in contact with electrodes, thus eliminating possible sources of contamination and allowing the operation of such plasma torches with a wide range of gases including inert, reducing, oxidizing, and other corrosive atmospheres. The working frequency is typically between 200 kHz and 40 MHz. Laboratory units run at power levels in the order of 30–50 kW, whereas the large-scale industrial units have been tested at power levels up to 1 MW. As the residence time of the injected feed droplets in the plasma is very short, it is important that the droplet sizes are small enough in order to obtain complete evaporation.