Open Access Article
Ali Khatibi
*ab,
Miryam Arredondoc,
Paul Maguire†
a and
Davide Mariotti
*d
aSchool of Engineering, Ulster University, Belfast, UK
bDiamond Light Source Ltd., Harwell Science and Innovation Campus, Didcot, UK. E-mail: ali.khatibi@diamond.ac.uk
cSchool of Mathematics and Physics, Queen's University Belfast, Belfast, UK
dDepartment of Design, Manufacturing & Engineering Management, University of Strathclyde, Glasgow, UK. E-mail: davide.mariotti@strath.ac.uk
First published on 27th November 2025
Nanostructured single-phase metal crystals with single and well-defined crystal structures exhibit unique, predictable, and stable properties that are distinct from those of multiphase crystals. However, synthesizing such pure nanocrystals is challenging, as bismuth exhibits multiple polymorphs and crystal phases that often prevent achieving monophase crystals, especially under atmospheric pressure. In this study, we present a gas-phase synthesis method using non-equilibrium plasma to produce high-purity, monophase bismuth nanocrystals (BiNCs) at atmospheric pressure. This approach employs a solid bismuth precursor, eliminating the need for hazardous solvents and offering a safer, more environmentally friendly alternative. By controlling plasma absorbed power and incorporating hydrogen to the process gas, localized melting and surface nucleation are promoted, resulting in the formation of BiNCs with a rhombohedral crystal phase. High-resolution transmission electron microscopy, X-ray diffraction and Raman spectroscopy confirmed the crystallinity of the BiNCs, exhibiting sharp faceting in some cases. X-ray photoelectron spectroscopy and energy-dispersive X-ray spectroscopy revealed that the nanocrystals were predominantly composed of elemental bismuth with minimal surface oxidation when exposed to the atmosphere.
Bismuth naturally exhibits multiple polymorphs and crystal phases, with the rhombohedral phase being the most stable.8,9 However, synthesizing BiNCs with a pure rhombohedral phase remains challenging due to bismuth's tendency to form several polymorphs under varying synthesis conditions.10–12 Polymorphism is greatly influenced by temperature,12 chemical environment and other factors during synthesis,13 often leading to mixed-phase products that compromise material performance.14,15 Solution-based synthesis methods, such as hydrothermal techniques,16 require precise control over reaction conditions to favor the formation of the desired phase and typically involve the use of hazardous metal–organic precursors, solvents and additives, which influence the nucleation and growth processes. Such chemicals are not only expensive but also pose significant environmental and safety concerns. Furthermore, such processes often necessitate additional purification steps to remove by-products, lowering yields and adding complexity to the overall process.5–7,13,16 The toxic waste generated from solvents and additives highlights the need for safer and more sustainable methods. Addressing the limitations of current synthesis techniques is essential for the reliable production of monophase BiNCs. The development of alternative methods that avoid hazardous chemicals and eliminate complex purification steps would simplify the synthesis and improve scalability, making BiNCs production more accessible for industrial-scale applications in various technological fields. Low-pressure synthesis techniques utilizing solid precursors, such as vapour deposition,12,17–20 pulse laser deposition21 and molecular beam epitaxy22,23 have demonstrated significant promise in producing Bi nanostructures. However, in most cases, these techniques have produced multiphase and polycrystalline bismuth structures.12,18–20 Furthermore, these methods require high-vacuum environments, which add operational challenges and costs.
In this study, we present a gas-phase synthesis technique using non-equilibrium atmospheric pressure plasma to produce monophase BiNCs. Our approach uses a solid bismuth precursor in a plasma environment, eliminating the need for hazardous chemicals and complex purification processes. The process exploits plasma's ability to induce localized melting and controlled crystallization at the surface of the sacrificial metal wire electrode. This method not only simplifies the experimental setup but also enables the rapid synthesis of highly crystalline, monophase BiNCs under atmospheric pressure. Our results confirm the formation of BiNCs with rhombohedral structure and some faceted morphologies with high purity. Additionally, we propose a mechanism for BiNCs formation, driven by plasma-induced localized melting and subsequent nucleation under non-equilibrium conditions. Our approach addresses key limitations of existing synthesis methods and offers insights into the development of a plasma-based process for a sustainable pathway for producing high purity monophase metal nanocrystals.
Helium with 1% H2 is used as the process gas with a constant flow rate of 1 standard litre per minute (sLm). Hydrogen initially acts as a cleaning agent, removing organic impurities and contaminants as well as native oxide from the surface of the Bi wire. Subsequently, hydrogen contributes to increasing the NC production rate. A Perspex frame provides mechanical support and keeps the vertical and radial position of the wire fixed to the frame.
To reduce the presence of oxygen or moisture in the synthesis process, the plasma reactor is held inside a stainless-steel chamber. Before synthesis, the chamber is evacuated and then filled with pure N2 gas under atmospheric pressure, which effectively prevents bismuth oxidation during the synthesis process. Each synthesis was carried out for 15 min and BiNCs were collected downstream on a substrate placed 0.8 cm below the capillary end (Fig. 1c and d).
SEM images of the wire surface (Fig. 2c) revealed the presence of Bi particles that had formed directly on the surface of the wire, exhibiting broad size distribution, ranging from as small as ∼10 nm to several micrometers in diameter. Notably, irrespective of their sizes, at an absorbed power of 3.5 W, the Bi particles collected on the silicon substrate visibly displayed faceted morphologies, unlike those synthesized at higher powers (4.2–4.7 W), compare Fig. 2a at 3.5 W with 4.2–47 W and Fig. S3a–S4 with Fig. S3b and c. In contrast, at higher absorbed powers, the Bi particles appeared smoother and more spherical (Fig. 2a at 4.2 W and 4.7 W, see also Fig. S3b and c).13,20 At powers higher than 4.7 W, the plasma became unstable, leading to significant contractions of the Bi wire, pulling away from the plasma, which resulted in the extinction of the plasma and the end of BiNCs formation. While synthesis of BiNCs was possible up to 4.7 W, under these conditions, the optimal operational parameters for the synthesis of BiNCs were determined to be at 3.5 W. It should be noted that, in addition to power, other process parameters can also play a role in shaping the synthesis outcome and, by extension, the properties of BiNCs. However, certain parameters may exhibit lower sensitivity, leading to minimal or negligible variations in the nanocrystal synthesis. The similarity between the particles collected on the substrate (Fig. 2a) and those observed on the wire surface (Fig. 2c) strongly suggests that the formation of BiNCs primarily occurs at the wire surface rather than in the gas phase. This indicates that the wire surface acts as the primary site for nucleation and growth, with the particles subsequently detaching and depositing onto the substrate. This may be specific of this synthesis method, with the Bi wire and under these conditions, as using other metallic sacrificial electrodes or other plasma conditions, the formation of nanoparticles in the gas-phase is also possible and has been observed.24–27
m (166) space group, with lattice constants of a = 4.537 Å and c = 11.838 Å,28,29 as illustrated in Fig. 3a and b. The equilibrium morphology of BiNCs, known as the Wulff shape (Fig. 3c), closely resembles the morphology of the BiNCs deposited on the silicon substrate at an absorbed power of 3.5 W (Fig. 2a) and further shown in Fig. 3d. According to Wulff's construction, the crystal adopts a shape that minimizes their surface energy, resulting in flat, intersecting surfaces at well-defined angles, forming facets, as seen in Fig. 3d and c. The presence of such well-defined facets indicates that the plasma induced crystal growth process enabled balanced growth rates along different crystallographic directions. The relative sizes and orientations of the BiNCs’ facets are determined by the crystal's internal structure and the surface energies associated with each crystallographic plane. This balance of surface energies leads to the formation of monophase BiNCs with a consistent rhombohedral structure. To further investigate the crystallinity and structure of the BiNCs, high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM) was employed. Fig. 3e–g display representative HAADF-STEM images of three different BiNCs, synthesized at 3.5 W, with their corresponding fast Fourier transforms (FFTs) as insets (see Fig. S5 for higher resolution images). The bright spots in each FFT indicate interplanar (d) spacings of ∼3.21 nm, ∼3.72 nm and ∼3.97 nm corresponding to the crystalline planes (012), (101) and (003), respectively. These values are consistent with those d-values expected for rhombohedral bismuth, confirming the monophase structure and high crystallinity of the BiNCs. This is supported by X-ray diffraction (XRD), Fig. 3h. The XRD peaks from the BiNCs sample align closely with reference peaks associated with the rhombohedral phase of mono-elemental bismuth (JCPDS, PDF-851329).18,19,30,31
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Fig. 3 Characterization of monophase, faceted BiNCs synthesized at 3.5 W. (a) and (b) Rhombohedral (R m (166)) crystal structure of elemental Bi viewed down the a and c axes, respectively. Structures generated using VESTA.32 (c) Expected Wulf shape (equilibrium shape) of rhombohedral Bi. (d) SE SEM image of faceted BiNCs; image acquired at 5 kV. (e)–(g) HAADF-STEM images of individual BiNCs with corresponding FFTs as insets, confirming the Rhombohedral phase of BiNCs. (h) XRD pattern of BiNCs (blue) and reference JCPDS, PDF-851329 (red), confirming their monophase nature. | ||
The peak intensities resemble the expected relative intensities of the reference pattern, with minor deviations (Fig. 3h). The differences in peak intensities can be attributed to the growth of the BiNCs with a preferential orientation along specific crystallographic planes. The enhanced intensity of the (012) reflection suggests a higher degree of crystallographic alignment along this plane, consistent with the nanoscale dimensions and surface-dominated characteristics of the synthesized BiNCs. Additionally, slight variations in relative intensities of other reflections, such as (003) and (101), can be attributed to the different morphology and size distribution of the nanocrystals, which influence their diffraction patterns. The appearance of double peaks, instead of single peaks, may result from the Cu Kα1/Kα2 source X-ray splitting due to spin–orbit coupling,33 a common feature reported for large single crystals where the XRD peak widths are relatively narrow and can be easily resolved. The observation of these sharp and distinct XRD peaks further confirms the high degree of crystallinity and monophase structure of the BiNCs.
STEM energy-dispersive X-ray spectroscopy (STEM-EDX) revealed the elemental composition of the BiNCs, Fig. 4a. The qualitative elemental maps highlight the presence of bismuth (Bi) in red, with minimal oxygen (O) content, in green. Fig. 4b presents an HAADF image of an individual BiNC overlayed with the elemental maps for Bi (M line) and O (K line). STEM-EDX line profiles (Fig. 4c) display a significantly stronger signal for Bi (M line) compared to O (K line). The extremely low and uniform oxygen signal across the crystal and grid (Fig. 4d: vacuum – A1, carbon support – A2, and inside the BiNC – A3) suggests that any oxygen present is primarily limited to the surface and cannot be attributed at the core composition of the nanocrystals, supporting the high purity and monophase nature of the BiNCs STEM-EDX spectra (Fig. 4d) were obtained from three different areas, as shown in Fig. 4b: on the carbon support of the TEM grid (A2), in the vacuum (A1) and inside the BiNC (A3). This confirms a very low oxygen content of the BiNCs. Moreover, if oxygen were incorporated into the core of BiNCs, it would cause a noticeable deviation in the fit of the crystallographic structure. However, as shown in Fig. 3, the XRD and STEM analyses confirm that this is not the case. X-ray photoemission spectroscopy (XPS) was conducted to examine the surface composition and potential oxidation of the BiNCs. We closely monitored the time the BiNCs were exposed to ambient air, approximately 4 minutes, during the transfer of the sample from the nitrogen-filled synthesis chamber to the XPS load chamber under vacuum. Fig. 4e displays the high-resolution XPS spectrum of the regions for Bi 4f for the BiNCs sample immediately after synthesis (top spectrum). The two peaks separated by 5.3 eV at binding energies of 156.7 eV and 162 eV correspond to the 7/2 and 5/2 spin–orbit components of elemental Bi. In contrast, the peaks observed at 158.7 eV and 164 eV are typically associated with Bi bonded to oxygen in the α-Bi2O3 phase. To confirm that this oxide layer forms after synthesis due to brief air exposure during sample transfer, we performed sputter cleaning on the sample using a monoatomic 2 keV Ar+ gun in an ultra-high vacuum for 45 seconds to remove the surface bismuth oxide. The XPS spectrum taken after sputtering (Fig. 4e, middle spectrum) shows a significant reduction in the oxide-related peaks, indicating that the oxidation was confined to the surface of the sample. After the sample was re-exposed to air for another 4 minutes, a subsequent XPS analysis was performed. The spectrum (Fig. 4e, bottom spectrum) displays the reappearance of the oxide peaks, consistent with the initial post-synthesis measurement, confirming rapid surface oxidation post-synthesis, upon short exposure to air (∼4 min).
Raman spectroscopy (Fig. 4f) further validated the rhombohedral phase of BiNCs, as indicated by two clear peaks centered at 69 cm−1 and 94 cm−1, assigned to the Eg and A1g phonon modes, respectively, in agreement with pure metallic BiNCs.9,18,30 In addition to the crystallinity and phase, the Raman spectrum shows impurities as well as the incorporation of oxygen in BiNCs. The low-intensity peak related to a Bi2O3 phase at 188 cm−1 highlights limited surface oxidation.9,10,34 Notably, using higher laser intensities or longer integration times during Raman spectroscopy can induce oxidation and phase transitions in BiNCs, as reported in the literature.30,34,35
The formation of monophase BiNCs in the atmospheric pressure plasma environment, as opposed to multiphase structures, can be attributed to the wire temperature and the presence of hydrogen in the process gas. While the synthesis of Bi nanoparticles has been achieved also without hydrogen, we have not observed monophase or faceted BiNCs when hydrogen was not used. Hydrogen radicals and ions dissociated and ionized in the gas-phase plasma can impact the plasma–surface interactions. These factors might play a significant role in stabilizing a single crystal phase during the nucleation and growth processes. Atomic hydrogen in the plasma for instance can dissolve in the molten surface and transfer heat to the melt through exothermic recombination reactions, enhancing vaporization and particle formation. This was observed for instance also when a similar plasma was in contact with a gold wire.37 hydrogen atoms dissolve into the molten gold wire, and their exothermic recombination reactions enhance the etching of the gold surface. This etching process results in the formation of Au vapor, which condenses to form nanoparticles.37 A similar mechanism has been also observed in Sn–Ag nanoparticle formation.38,39 Atomic hydrogen is found to dissolve in the molten metal surface and contribute to the formation of metal hydrides. These hydrides play a critical role in enhancing the vaporization rate of specific metals, such as Sn. The recombination of hydrogen atoms within the molten metal not only facilitates the formation of hydrides but also transfers additional heat to the melt, thereby accelerating vaporization. Our results suggest the non-equilibrium plasma environment provides a unique set of conditions for crystal growth. This balance ensures that once the initial nuclei of BiNCs form, they grow into larger crystals with a consistent phase, rather than transitioning into multiple phases as might occur in less controlled environments.
Supplementary information (SI) is available. See DOI: https://doi.org/10.1039/d5nr03611a.
Additional results and raw data underlying this work are available in the SI or on request following instructions provided at [insert DOI].
Footnote |
| † Current address: School of Physics & Astronomy, University of Glasgow, UK. |
| This journal is © The Royal Society of Chemistry 2025 |