We show a low temperature gas-phase synthesis route to produce faceted aluminum crystals in the aerosol phase. Use of triisobutylaluminum whose decomposition temperature is below the melting point of elemental aluminum enabled us to grow nanocrystals from its vapor. Combustion tests show an increase in energy release compared to commercial nanoaluminum. Production of aluminum in an oxygen free environment resulted in a bare aluminum surface that was passivated in separate experiments with nickel and iron by decomposition of their carbonyl precursors.
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