Synthesis of Submicron-Sized Spherical Silica-Coated Iron Nickel Particles with Adjustable Shell Thickness via Swirler Connector-Assisted Spray Pyrolysis

Silica-coated iron nickel (FeNi@SiO₂) particles have attracted significant attention because of their potential applications in electronic devices. In this work, submicron-sized spherical FeNi@SiO₂ particles with precisely controllable shell thickness were successfully synthesized for the first time using a swirler connector-assisted spray pyrolysis system, comprising a preheater, specific connector, and main heater. The results indicated that the thickness of the SiO₂ shell can be tuned from 3 to 23 nm by adjusting the parameter conditions (i.e., preheater temperature, SiO₂ supplied amount). Furthermore, our fabrication method consistently yielded a high coating ratio of more than 94%, indicating an excellent quality of the synthesized particles. Especially, to gain an in-depth understanding of the particle formation process of the FeNi@SiO₂ particles, a plausible mechanism was also investigated. These findings highlight the importance of controlling the preheater and SiO₂ supplied amount to obtain FeNi@SiO₂ particles with desirable morphology and high coating quality.