The dust grain size distribution (GSD) likely varies significantly across star-forming environments in the Universe, but its impact on star formation remains unclear. This ambiguity arises because the GSD interacts nonlinearly with processes like heating, cooling, radiation, and chemistry, which have competing effects and varying environmental dependencies. Processes such as grain coagulation, expected to be efficient in dense star-forming regions, reduce the abundance of small grains and increase that of larger grains. Motivated by this, we investigate the effects of similar GSD variations on the thermochemistry and evolution of giant molecular clouds (GMCs) using magnetohydrodynamic simulations spanning a range of cloud masses and grain sizes, which explicitly incorporate the dynamics of dust grains within the full-physics framework of the STARFORGE project. We find that grain size variations significantly alter GMC thermochemistry: the leading-order effect is that larger grains, under fixed dust mass, GSD dynamic range, and dust-to-gas ratio, result in lower dust opacities. This reduced opacity permits interstellar radiation field and internal radiation photons to penetrate more deeply. This leads to rapid gas heating and inhibited star formation. Star formation efficiency is highly sensitive to grain size, with an order-of-magnitude reduction when grain size dynamic range increases from 10−3–0.1 μm to 0.1–10 μm. Additionally, warmer gas suppresses low-mass star formation, and decreased opacities result in a greater proportion of gas in diffuse ionized structures.
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