Zirconia powders with grain sizes between 4 and 35 nm were synthesized
by the gas condensation technique. Different qualities (grain size, g
rain size distribution) of powders have been observed and can be attri
buted to different synthesis conditions (mainly temperature gradients)
within the UHV chamber. The existence of necks between single particl
es has been observed. These necks are due to a first sintering process
during the oxidation of the metal/suboxide clusters condensed on the
walls in the synthesis chamber. Several stages of this sintering proce
ss are documented by high-resolution micrographs. Furthermore, some pa
rticles exhibit a shell-like structure with monoclinic ZrO2 in the out
er region and tetragonal ZrO2 in the inner region. This is an indicati
on of (i) the martensitic phase transition character of zirconia in ge
neral, and (ii) the existence of a critical particle size in n-ZrO2 re
sponsible for the metastability of a tetragonal polymorph in nanosized
zirconia powder. Lattice distortions in some directions can be conclu
ded from image reconstruction of the digitized micrograph of a single
nanosized ZrO2 particle.