Synthesis of aluminium nanoparticles by arc plasma spray under atmospheric pressure

► A customized arc-plasma spraying based system has been designed and implemented. ► The system is relatively simple, robust and operates at atmospheric pressure. ► Preparation of aluminium nanoparticles from micron-sized powder was successful. ► Various nano-sized distributions were possible depending on operating parameters. ► Optimization of the proposed design will lead to higher efficiencies and throughput.