We show a low temperature gas-phase synthesis route to produce faceted aluminum crystals in the aerosol phase Use of tnisobutylaluminum whose decomposition temperature is below the melting point of elemental aluminum enabled us to grow nanocrystals from its vapor TEM shows both polyhedral crystalline and spherical particle morphologies but with the addition of an annealing furnace one can significantly enhance the production of just the polyhedral particles The results on surface passivation with oxygen suggest that these nanocrystals are less pyrophoric than the corresponding spherical aluminum nanoparticles and combustion tests show an increase in energy release compared to commercial nanoaluminum (C) 2010 Elsevier BV All rights reserved