Powder Blends Research Articles

Network structured nano-TiB/Ti composites coating on Ti64 alloy with improved wear properties by direct laser deposition

In this paper, the creation of the titanium matrix composites (TMCs) coating involved the usage of direct laser deposition (DLD) by applying the ball-milling treated blend of TiB2 and Ti64 powders. Systematic investigation was carried out to compare the microstructure, microhardness, and sliding wear mechanism of TMCs coating with that of the Ti64 substrate. The incorporation of the boron element successfully led to significant refinement of α grains. The TiB2 reacted completely with Ti to form acicular nano-TiB whiskers (TiBw) that were distributed in a network structure. The boundary connecting the TiB and α-Ti exhibits the coherent and semi-coherent interface, wherein a direct interatomic bond is established without any interfacial phase present. The microhardness of TMCs coating was measured at 473.9 HV0.025, which was 1.34 times greater as compared to the microhardness of the Ti64 substrate. The TMCs coating exhibited a noteworthy reduction in wear rate, decreasing from 8.535 × 10−6 mm3/(N·m) to 0.239 × 10−6 mm3/(N·m). In addition, the wear track dimension also demonstrated a considerable decrease, further highlighting the excellent wear resistance of the TMCs coating. The presence of reticular TiBw in the TMCs coating effectively mitigated adhesive wear sensitivity while increasing the prevalence of abrasive wear mechanisms.

Application of a wavelength angle mapper for variable selection in iterative optimization technology predictions of drug content in pharmaceutical powder mixtures

Process analytical technology (PAT) is an essential tool within pharmaceutical manufacturing to ensure consistent quality and maintain process control. Near-infrared (NIR) spectroscopy is one of the most popular PAT techniques, particularly for monitoring active pharmaceutical ingredient (API) concentrations. To interpret the spectral outputs of NIR spectroscopy, advanced multivariate models are required. Calibration-free models such as iterative optimization technology (IOT) algorithms are increasingly of interest, due primarily to their reduced material and time burdens. Variable/wavelength selection is a common method to improve prediction performance and robustness for IOT by focusing on spectral regions with the most relevant information. However, currently proposed wavelength selection approaches rely on training sets for optimization, therefore reducing or removing the advantages of IOT over empirical calibration-dependent models. In this work, a true calibration-free wavelength selection method is proposed based on measuring the difference between individual wavelengths of a mixture spectra and the net analyte signals via a wavelength angle mapper (WAM). An extension of the WAM utilizing a spectral window of wavelength instead of individual wavelengths, called SWAM, was also developed. However, the SWAM method does require a small training set to optimize wavelength selection parameters. The WAM and SWAM methods showed similar prediction performance for API in pharmaceutical powder blends when compared against other calibration-dependent models and the base IOT algorithm.

Ultrastrong Ti–6Al–4V composite with hierarchical microstructure through two-step ball milling and pressureless sintering

We report a new hierarchical microstructure in ultrastrong Ti–6Al–4V composite with TiC reinforcement via pressureless sintering. Specifically, powder sintered contained pre-introduced nano TiC particles, which were generated by first ball milling of blended powders of 60Al40V medium and minor Ti and subsequent ball milling with cyclohexane. The hierarchical microstructure consisted of primary thick β-Ti laths surrounding coarse equiaxed α-Ti zones, which consisted of cellular structures with ultrafine equiaxed α-Ti matrix and nano/ultrafine β-Ti lamellar. Essentially, the hierarchical microstructure originated from the nano TiC particles inhibit β-Ti grain growth and provide nucleation sites for α-Ti grains. Surprisingly, the hierarchical composite exhibits ultrahigh tensile yield strength, far superior to those of Ti–6Al–4V alloy and its composites by sintering. Fundamentally, the hierarchical microstructure and interface S-phase layers containing stacking faults were responsible for the ultrahigh yield strength. The results provide a new strategy to fabricate ultrastrong Ti matrix composites for demanding structural application.

Flow-through Gas Phase Photocatalysis Using TiO2 Nanotubes on Wirelessly Anodized 3D-Printed TiNb Meshes.

In this work, for the first time 3D Ti-Nb meshes of different composition, i.e., Ti, Ti-1Nb, Ti-5Nb, and Ti-10 Nb, were produced by direct ink writing. This additive manufacturing method allows tuning of the mesh composition by simple blending of pure Ti and Nb powders. The 3D meshes are extremely robust with a high compressive strength, giving potential use in photocatalytic flow-through systems. After successful wireless anodization of the 3D meshes toward Nb-doped TiO2 nanotube (TNT) layers using bipolar electrochemistry, they were employed for the first time for photocatalytic degradation of acetaldehyde in a flow-through reactor built based on ISO standards. Nb-doped TNT layers with low concentrations of Nb show superior photocatalytic performance compared with nondoped TNT layers due to the lower amount of recombination surface centers. High concentrations of Nb lead to an increased number of recombination centers within the TNT layers and reduce the photocatalytic degradation rates.

Cu-10 wt.% Al Alloys Produced by Spark Plasma Sintering of Powder Blends and a Mechanically Alloyed Mixture: A Comparative Investigation

Cu–Al bronzes are interesting metallic materials, demonstrating higher hardness, higher wear resistance, higher corrosion resistance and a lower friction coefficient as compared with unalloyed copper. The powder metallurgy approach to the fabrication of these alloys presents opportunities to tailor their phase composition and grain size. In the present work, the structural characteristics, phase composition and properties of Cu-10 wt.% Al alloys obtained by spark plasma sintering (SPS) of powder blends and a powder obtained by mechanical alloying (based on Cu(Al) solid solution) are reported. Alloys with different interaction degrees between the metals were obtained by SPS. The blends demonstrated better sinterability than the mechanically alloyed powder: a nearly fully dense alloy was obtained by SPS of the blend at 480 °C, whereas a temperature of 800 °C was necessary to consolidate the mechanically alloyed powder. The hardness and electrical conductivity of the sintered alloys were comparatively analyzed. It was shown that the Cu-10 wt.% Al alloys obtained without the mechanical alloying stage possess hardness and electrical conductivity comparable to those of the alloys obtained from the mechanically milled powder.

Assessing the feasibility of using an irregularly shaped Ta and spherical Ti bimodal powder blend on the powder spreadability process in powder bed fusion systems

The cost of additive manufacturing can be reduced if economical non-spherical powders are used. However, current flowability tests are inadequate to determine whether these powders can flow and spread well in powder bed systems. This paper presents a novel tool called the Universal Powder Bed designed to analyse the layer-spreading process of an electron beam melting system. The spreadability and feasibility of using a novel bimodal powder comprising of irregularly shaped tantalum and spherical titanium is investigated against three measures: area fraction of build surface covered with powder, surface roughness and composition of the powder bed. The characterisation techniques revealed that increasing layer thicknesses and slower rake speeds produced more efficiently packed powder layers and decreased the effects of segregation between opposite sides of the powder bed. This study shows that despite the segregation observed with bimodal powders, acceptable levels of spreadability can be produced by refining the spreading parameters.

Towards the additive manufacturing of Zr-based metallic glasses using liquid phase sintering: Reactivity and phase transformation kinetics at the crystalline/amorphous interface

Bulk metallic glasses (BMG) present great potential for high-tech applications considering the excellent mechanical and corrosion properties. The on-going development of powder additive manufacturing techniques offers the opportunity to produce rather large parts composed of BMG. Relative to the sinter based additive manufacturing techniques, the sintering of a Zr-based BMG (AMZ4, Zr59,3Cu28,8Al10,4Nb1,5) using Zn-based additives was identified as promising: Zn alloys have indeed a melting point (Tm,Zn = 419, 5∘C) lower than the crystallization temperature of the BMG (Tx ≃ 470∘C). Here, the study focuses on the understanding of the reactivity between AMZ4 and Zn as a function of temperature and time. A powder blend and a model interface AMZ4/Zn were studied combining post-mortem characterizations (SEM, EDX, XRD, micro-hardness…) with in situ characterization (DSC). Experimental construction of time-temperature-transformation diagram shows that there is a temperature/time window where sintering is permitted without crystallization. Beyond, an intermetallic phase is formed at the interface between the BMG and Zn, this phase was identified in terms of shape, composition and crystallography. A growth mechanism was proposed combining thermodynamic and kinetic aspects.

Solid-state blending for the preparation of porous eco-friendly PCL membranes: Potential for filtration applications

Cryomilling is a promising method for fabricating polymeric blend and composite powder raw materials for various subsequent manufacturing processes. In this study, biodegradable porous membranes were fabricated from poly (ε-caprolactone) (PCL) using the cryomilling/hot pressing/porogen leaching approach. Powder mixtures of six different model compositions were compounded by cryomilling; thereafter, films were fabricated by hot-pressing. Poly (ethylene-oxide) (PEO) and salt were utilized as eco-friendly porogens in these mixtures, which were dissolved in water to introduce porosity in the films. Wood sawdust (WSD) and alum were investigated as fillers potentially capable of manipulating the hydrophilicity, mechanical and antimicrobial properties of the membranes. The morphological, hydrophilicity, mechanical, and filtration efficiency properties were explored and compared to those of commercial laboratory microfiltration (MF) membranes. SEM analysis revealed dense membrane skins for all compositions, along with lamellar porous structures. Mean pore radius ranged from 0.15 to 0.21 μm, which is within the MF pore size range. Water contact angle measurements averaged 70° and decreased with the addition of WSD and alum, indicating increased hydrophilicity. Tensile test results showed a decrease in mechanical properties, with higher porosities and with the addition of WSD. Adding alum (≥10 wt%) resulted in embrittled membranes. Filtration performance was evaluated in terms of pure water flux and turbidity reduction for textile wastewater, and it compared favorably to commercial membranes. In conclusion, this study has successfully introduced a new facile and versatile membrane fabrication approach.

Achieving high strength in selective laser melting AlSi10Mg alloy by adding microsized pure Cu particles

In this work, a high-strength Al–Cu–Mg–Si alloy was prepared by a selective laser melting (SLM) process with blended powders consisting of AlSi10Mg and microsized pure Cu powders. The influence of Cu addition on the microstructure and mechanical properties of AlSi10Mg alloy has been systematically investigated. The Al–Cu–Mg–Si alloy has a hardness of 173 HV, an ultimate tensile strength of 732 MPa, and a yield strength of 389 MPa, reaching the level of high-strength aluminum alloys. Such increase in the strength and hardness can be attributed to the refinement of eutectic network, enhanced solid solution strengthening and elimination of fracture-prone heat affected zone (HAZ). In addition, the formation of the GP zone caused by adding Cu promotes the precipitation of Si particles within the eutectic network, and Si particles, as the non-shear deformed second-phase, can significantly increase the Orowan strengthening effect. After aging at 180 °C for 2 h, the hardness and yield strength of the alloy are increased to 183 HV and 522 MPa respectively. The presence of the θ′-Al2Cu phase and the high-density of Si particles after 2 h of peak aging further increases the strength and hardness of the alloy.

Tropical Red Fruit Blend Foam Mat Drying: Effect of Combination of Additives and Drying Temperatures

Foam mat drying is a widely used technique for liquid products because it has a number of advantages; however, for an efficient process, the choice of additives and temperatures is extremely important. The objective of this study was to evaluate the effect of additives and drying temperatures on the powders obtained from the blend of tropical red fruits, such as acerola, guava, and pitanga. The foam formulations were prepared by mixing the pulps of the three fruits in equal proportions (1:1:1), all added with 6% albumin and 1% stabilizing agent: E1, gum Arabic; E2, guar gum; E3, gelatin. The combinations were subjected to beating, and subsequently, they were dried in an oven with forced air circulation at four temperatures (50 to 80 °C), with a mat thickness of 0.5 cm. The obtained powders showed low levels of water and water activity and high levels of bioactive compounds, colors with a predominance of yellow, intermediate cohesiveness, poor fluidity, and solubility above 50%. The best temperature for obtaining the powders was 60 °C. The formulation that produced the best results for the production of the tropical red fruit blend powder was the combination of albumin and gelatin.

Powder metallurgy processing of Nb-modified near β titanium alloys prepared with elemental powders

ABSTRACT Near β Ti alloys typically show high specific strength and provide a wide spectrum of mechanical properties with different heat treatments. In this work, a commercial near β Ti alloy Ti-5553 (Ti-5Al-5V-5Mo-3Cr-0.5Fe) was prepared through powder metallurgy using the blended elemental powder approach. Additionally, alloy modifications with 6 wt.% Nb (Ti-6Nb-5Al-2.5V-5Mo-3Cr-0.5Fe) and 12 wt.% Nb (Ti-12Nb-5Al-5Mo-3Cr-0.5Fe) were investigated. Specimens were prepared by uniaxial cold compaction of blended powders at room temperature with sintering conducted at 1300°C for 2 h under Ar atmosphere. Microstructure investigation revealed reasonable homogenisation of alloying elements and colony sizes in the order of 80-100 μm with porosity below 10%. Moreover, the bending strength of as-sintered Ti-12Nb-5Al-5Mo-3Cr-0.5Fe was about 850 MPa and the micro-Vickers hardness was approximately 370 HV. The alloy modifications with Nb increased strength without loss in flexural strain.

Formulation, Development and Evaluation of Extended- Release Tablets of Carbamazepine

The current work sets out to design and develop a carbamazepine (CBZ) extended-release tablet in the treatment of epilepsy using wet granulation technology. The tablets were prepared using HPMC K 100M and ethyl cellulose as hydrophilic and hydrophobic polymers, respectively. The effect of the concentration of the polymer was studied. The studies indicated that the drug release can be modulated by varying the concentration of the polymer. Tapped density, bulk density, angle of repose, Hausner's ratio, and Carr's index were all calculated for powder blends. The prepared trial batches of tablets were first characterized for hardness, friability, weight variation, and drug content to select an optimized batch. An in-vitro dissolution study of the optimized batch (F4) was carried out in distilled water using a USP Type I (basket type) dissolution apparatus at 100rpm. The optimized formulation (F4) showed a drug content of 99.51%. In-vitro drug release of optimized formulation was found to be 88.10% in 24hours. The optimised formulation demonstrated release for up to 24 hours. The optimised formulation's stability was studied for three months at 40±2ºC/75±5% RH, 30±2ºC/65±5% RH, and 25±2ºC/60±5% RH, and the prepared tablets showed no remarkable effect from the stability study. The results suggest that the developed extended-release tablets of CBZ (400 mg) could perform as therapeutically equivalent alternatives to conventional dosage forms, leading to better patient compliance.

Investigation on surface water treatment using blended moringa oleifera seed and aloe vera plants as natural coagulants

The implementation and careful adaptation of treatment plants is currently the most common method for enhancing water quality, especially for large-scale supplies. Nowadays, natural coagulants are used for water treatment due to their environmental friendliness. moringa oleifera and Aloe vera plants are the known natural coagulants used for water. The main goal of this study was to evaluate the removal efficiency of color, turbidity, TDS, COD, and phosphate from surface water by utilizing the blended powder of moringa oleifera seeds (MOS) and Aloe vera plants (AVP). In this study also, pH, stirring speed of the jar test, coagulant dosage, and settling time were also considered as influencing factors on the removal percentages. The blended powder of moringa oleifera (MOS) and Aloe vera plants (AVP) removed color (87.1%), turbidity (88.5%), TDS (92.1%), COD (52.6%), and phosphate (93.9%) at different operating parameters at optimum condition. Furthermore, experimental data were statistically and mathematically analyzed using a central composite design (CCD) from response surface methodology (RSM), revealing that the quadratic model was significant for COD and phosphate removal. The model was also valid for the COD and phosphate removal based on the coefficient of determination, but the quadratic model for the removal of color, turbidity, TDS, and COD was aliased such that it is not appropriate for further investigation.

High compressive plasticity refractory medium entropy alloy fabricated by laser powder bed fusion using elemental blended powders

High plasticity light weight refractory complex concentrated alloys (RCCAs) are the best alternative to replace nickel base alloy. The advantages of additive manufacturing (AM) in the rapid and direct forming of complex structure RCCA parts are beyond the reach of traditional techniques. In this work, a simple composition of refractory metal elementals was carefully designed. The single-phase BCC Nb–40Ti–20Ta refractory alloy was fabricated by laser powder bed fusion (LPBF) using elemental blended powders, it has excellent compression plasticity (e>80%) and strength at both room and high temperatures. The effects of laser parameters and treatment process on microstructure and mechanical properties of the Nb–40Ti–20Ta alloy were investigated. The experimental results show that the density and hardness of the alloy are approximately positively correlated with the laser energy density. The laser parameters have a significant effect on the microstructure. Too low energy density leads to the formation of some unmelted powders, while too high power density results in the transformation of micro-pore into larger keyhole. The laser short action time and too rapid cooling rate of the molten pool induce the micro-segregation in grains. β-phase dendrites are formed from inside to outside while the high melting point Ta acts as the center, and Ti is enriched in the inter-dendrite region. The shapes of grains are divided into two types: columnar and cellular substructures. The single phase BCC Nb–40Ti–20Ta alloy has ultra compressive plasticity whether annealed or not. The results show that the novel alloy prepared by LPBF possesses excellent mechanical properties. This work provides an important progress for the preparation high compressive plasticity RHEAs by LPBF using elemental blended powders.

Effect of process parameters and formulation properties on the lead-lag between in-line NIR tablet press feed frame and off-line NIR tablet measurements

The use of in-line near-infrared (NIR) measurements for tablet potency monitoring and diversion was studied. First, the optimal sample size for in-line NIR measurements inside the feed chute and the dosing and filling chamber of the tablet press feed frame was determined to allow proper comparison between these different measurement positions. Because of the considerably longer measurement time needed to obtain the same sample size inside the feed chute compared to the feed frame, the possibility of powder segregation inside the feed chute and the additional powder mixing inside the feed frame, the latter is preferred over the feed chute for in-line blend potency monitoring. Next, a design of experiments (DoE) was performed to evaluate the effect of paddle speed, turret speed, overfill level and formulation properties upon the lead-lag and the time it takes before the powder blend that is expelled at the dosing station is measured by the NIR inside the dosing chamber. Lead-lag is defined as the difference in time and API concentration between the measured in-line NIR response inside the filling chamber of the feed frame and the off-line NIR tablet response. Paddle speed and turret speed were the only compression parameters affecting lead-lag. Lead-lag decreased with increasing paddle speed for the first formulation. For the second formulation, lead-lag decreased with decreasing paddle speed and/or increasing turret speed. Formulation properties did not have an effect on the lead-lag. The in-line NIR response inside the dosing chamber of the feed frame was found to be closely following the tablet NIR response. Therefore, the dosing chamber could be used as an additional in-line NIR position for tablet potency monitoring and diversion. It can provide an extra layer of confidence about the final tablet quality. To demonstrate this potential benefit of simultaneous in-line NIR measurements inside the filling and dosing chamber of the feed frame, a tableting experiment was performed where a surrogate API spike was introduced into the product stream to mimic a potential process disturbance. The in-line NIR measurements inside the filling chamber allow diverting tablets in-time when the blend potency crosses the predefined control limits. And because the NIR response inside the dosing chamber closely follows the tablet NIR response, tablet diversion can discontinue when the blend potency inside the dosing chamber is again within the control limits. This could increase the yield of the tableting process by avoiding a longer than needed wash-out period and rejecting tablets that meet the release limits.

Optimization Method of Whole Wheat Flour, Soybean Flour, Oyster Meat Powder for Nutrient- Dense Composite Flour

Aim: To study the production of Nutrient – Dense Composite Flour from the blends of whole wheat flour, soybean flour (full fat) and oyster meat powder.
 Study Design: The study was design using the D-optimal combination design of Response Surface Methodology (RSM).
 Place and Duration of Study: The study was carried out at Department of Food, Nutrition and Home Science, University of Port Harcourt (Processing of raw materials) and the Department of Food Technology, Federal Institute of industrial research Oshodi, Lagos (Analysis of raw materials) between October 2021 and August 2022.
 Methodology: The raw materials were each processed to have wholesome flours, and then they were combined according to the matrix generated, which had ranges of 70 – 100%, 0 – 22%, and 0 – 8% for whole wheat flour (WWF), soybean flour (SBF) and oyster meat powder (OMP) respectively.
 Results: The design was used to assess the significance (5% probability) of the moisture, fat, and protein content, which ranged from 8.09 to 11.37%, 1.80 to 8.52% and 9.70 to 19.07% respectively; the water absorption (72.00 - 79.10BU), dough stability (9.3 - 17.5BU) and mixing tolerance index (25 - 50BU); and lightness and yellowness, which ranged from 65.48 - 83.2 and 13.77 - 23.58 respectively, of the flour blends. Protein content, water absorption dough stability, and mixing tolerance index were prioritized while moisture content, fat content, and yellowness were minimized for the numerical optimization of the responses. This study highlights the possibilities of utilizing non-conventional raw materials in the production of composite flour with balance nutritional and baking qualities.
 Conclusion: The best flour combination was 72.51% whole wheat flour, 19.63% soybean flour, and 7.86% oyster meat powder.

FORMULATION AND EVALUATION OF SINTERED GASTRORETENTIVE TABLETS OF VILDAGLIPTIN USING DESIGN OF EXPERIMENT

Objective: The purpose of the study was to formulate and evaluate sintered gastro retentive tablets of Vildagliptin using the design of experiments. Methods: Direct compression is the process by which tablets are compressed from powder mixture of API and suitable excipients and compression was done by an automatic punching machine using 6 mm punch. Prepared tablets were kept in the hot air oven at three different temperatures of 50°C, 60°C, 70°C for three different periods of 1, 2, 3 h. Results and Discussion: The physiochemical evaluation results of the powder blend of all the trails pass the flow properties and compression properties and are of uniform density (i.e., Angle of repose, Bulk density, Compressibility index, Hausner’s ratio). Among all the Formulations, Formulation F7 showed better results such as Angle of repose F7(29.9), Hausners ratio of F7(1.18), and compressibility index of F7 (15.6) which indicate the good flow properties. The prepared tablets were evaluated for the post compression properties such as thickness, hardness, Weight variation, friability, and drug content found within limits. Each formulation was analyzed spectrophotometric ally, and each formulation showed drug content >80%. Formulation F7 consisting of polymers (stearic acid, carnauba wax) and gum (xanthan gum) showed percentage drug release of 95.8 at 12 h. The developed formulations were optimized by Box Behnken design to achieve desired properties. Conclusion: Vildagliptin has good solubility in acidic pH. It has good absorption from an acidic environment. By preparing floating tablets of Vildagliptin, its bioavailability can be enhanced as more amount drug will be absorbed from stomach. Vildagliptin is having high melting point of 158–160°C which is best suitable for the thermal sintering technique. The aim of the present study to formulate and evaluate Sintered Gastro retentive tablets of Vildagliptin using Design of Expert was successfully achieved.

Combustion characteristics of biocoke with added Al powder in oxygen-enriched atmosphere

In this paper, we propose the application of biocoke, which is a high-density solid biofuel, as a solid fuel for hybrid rockets. In this study, we aim to investigate the effect of added aluminum powder on the combustion behavior of biocoke to improve the combustion rate. The average flaming combustion rate, total combustion time, and Al powder reaction ratio are calculated from the mass change during combustion. The results show that the increase in Al powder content accelerates the rate of flaming combustion. The flaming combustion rate is determined by the Al content and oxygen concentration. The combustion rate improvement effect of Al powder blending is approximately 1.15 times higher at 30 mass% Al content. The combustion time does not decrease because the Al powder particles inhibit oxygen diffusion at 30 mass% Al content. The results of this study indicate that another method is needed to increase the combustion rate while maintaining high density.

Effect of glidant in the formulation of goat milk tablet

Milk is an essential part of children's diets and can help them grow and develop properly. Goat milk is an excellent source of nutrition, providing a number of important vitamins and minerals. Despite this, the consumption of milk decreases as children grow older, mainly due to the availability of alternative drinks and an aversion to its taste. Therefore, this study aims to develop goat milk in the form of tablets using direct compression methods. This study focuses on improving goat milk's flowability and compressibility by changing the talc amount as a glidant used in the formulation. Six formulations containing 2% to 12% talc were prepared, designated F1 through F6. The results showed that adding talc as the glidant component improved the flowability of the blended powder, with the highest flowability observed at 10% talc concentration in formulation F5. It improved the flowability from “very, very poor” to “passable”, as determined by the USP standard. However, the flowability drops with excess glidant concentration, which is 12%. This study highlights the importance of glidants in improving powder flowability and the need for using suitable concentrations to prevent negative effects on the product's quality. Thus, pure goat milk in the form of liquid can be replaced by goat milk tablets prepared by the direct compression method. The compressibility and flowability of the powder mixed with the goat milk formulation were successfully improved, with good tablet hardness, uniformity of weight and a low friability index.

Drug Phase Transformation and Water Redistribution during Continuous Tablet Manufacturing: A Case Study of Carbamazepine Dihydrate.

In recent years, continuous tablet manufacturing technology has been used to obtain regulatory approval of several new drug products. While a significant fraction of active pharmaceutical ingredients exists as hydrates (wherein water is incorporated stoichiometrically in the crystal lattice), the impact of processing conditions and formulation composition on the dehydration behavior of hydrates during continuous manufacturing has not been investigated. Using powder X-ray diffractometry, we monitored the dehydration kinetics of carbamazepine dihydrate in formulations containing dibasic calcium phosphate, anhydrous (DCPA), mannitol, or microcrystalline cellulose. The combined effect of nitrogen flow and vigorous mixing during the continuous mixing stage of tablet manufacture facilitated API dehydration. Dehydration was rapid and most pronounced in the presence of DCPA. The dehydration product, amorphous anhydrous carbamazepine, sorbed a significant fraction of the water released by dehydration. Thus, the dehydration process resulted in a redistribution of water in the powder blend. The unintended formation of an amorphous dehydrated phase, which tends to be much more reactive than its crystalline counterparts, is of concern and warrants further investigation.