A method and apparatus for producing uniform, monosize ceramic particles forming the microsize particles by vapor condensation or ultrasonic cavitation. Organometallic liquids are directed to an aerosol generator where a droplet stream is projected in free flight within a reaction chamber and a particle sorter. Through the process of sorting the droplets according to their velocity in flight, monosize droplets are collected. The particles may be reacted prior to or after sorting and collection to form the monosize ceramic particle of interest. Sintering aids are introduced into the process to produce ceramic particles capable of improved green body formation.
Stephen T. Wellinghoff; Thomas E. Owen