Flame synthesis of tungsten oxide nanostructures on diverse substrates

One-dimensional (1D) tungsten oxide nanostructures show great potential for applications in the areas of batteries, photoelectrochemical water-splitting, electrochromic devices, catalysts and gas sensors. 1D tungsten oxide nanostructures are currently synthesized by physical or chemical vapor deposition, which are limited by low temperatures, the need for vacuum conditions, frequently expensive catalysts, and difficulty in scaling up for mass-production. These limitations, however, can be overcome by flame synthesis. Here, using a co-flow multi-element diffusion burner, we demonstrate the atmospheric, catalyst-free, rapid, mild and scalable flame synthesis of diverse, quasi-aligned, large density, and crystalline tungsten oxide nanostructures on a variety of substrates. Specifically, under fuel-rich conditions, monoclinic 1D W₁₈O₄₉ nanowires and nanotubes were grown on tungsten, iron, steel and fluorinated tin oxide (FTO) substrates, with controlled diameters ranging from 10 to 400 nm and axial growth rates ranging from 2 to 60 μm/h. Monoclinic 1D WO₃ nanowires and nanotubes were grown, instead, on silicon and silicon dioxide substrates. Under fuel-lean conditions, diverse WO₃ nanostructures, including monoclinic 1D nanowires, cubic 2D nanobelts and monoclinic 3D nanocones were grown on tungsten and FTO substrates. The success of this versatile flame synthesis method is attributed to the large tunability of several synthesis parameters, including the flame stoichiometry, the tungsten source and growth substrate temperatures, the tungsten oxide vapor concentration, and the material of the growth substrate. This flame synthesis method can be extended to synthesize other 1D transition metal oxides as well, enabling many large-scale electronic and energy conversion applications.