Take note of the comments regarding concentration and temperature. Harold was right in chilling the Gold Chloride.
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One of the most important aspects of this invention resides in the use of a reducing agent selected from the group consisting of potassium sulfite, sodium sulfite and mixtures thereof. While many other reducing agents are well known and could be used to precipitate a gold powder, it has been found that under specified conditions, this class of reducing agents precipitates the gold powder of this invention having a specified size, shape and density. The amount of reducing agent utilized is not critical; but to obtain maximum precipitation, an excess is generally used.
Another important feature of this invention involves maintaining the temperature of the solution within the range of 0°-30°C. Of course, below 0°C. the solution has a tendency to freeze. Above 30°C., the particles of gold become exceedingly fine and the bulk density becomes too low for purposes of producing good electrical properties. The preferred temperature is within the range of 10°-20°C.
The precipitation (reduction) is performed by adding reducing agent(s) to the aqueous gold chloride solution. The addition of the reducing agent to the gold chloride solution should be carried out as rapidly as possible to provide maximum efficiency of the overall process. It is pointed out that the reducing agent is added to the aqueous gold chloride (not vice versa) to provide gold particles having the proper particle size and shape. For example, the particles become too small when an aqueous gold chloride solution is added to a solution of the reducing agent. Also, although not necessary, it is preferred to agitate the solution while the precipitation reaction takes place. This provides a greater contact between the reducing agent and the gold chloride, and results in a complete precipitation in a shorter period of time.
The process of this invention is not particularly sensitive to the concentration of the reactants. Therefore, concentrated solutions or dilute solutions of the gold chloride and reducing agent may be used. However, somewhat larger particles are obtained when higher concentrations of gold chloride and reducing agent are utilized. Typical and preferred concentrations of gold chloride and reducing agent in their respective solutions are within the ranges of 40-70 gms/liter and 100-200 gms/liter.