Increase In Particle Size Research Articles

Structural and morphological features of magnetron nanofilms of TaN with different thicknesses

Purpose of research. Study of morphological and phase changes in the structure of tantalum nitride nanofilms formed by magnetron reactive sputtering on a silicon substrate.Methods. Magnetron sputtering on a silicon substrate was performed using the MVU TM-Magna T setup with the sputtering time parameter changing from 300 to 900 sec, and also with constant power parameters of 500 W and working gas pressure of Ar 0,5 Pa. The morphological and phase changes in the structure of tantalum nitride nanofilms were studied using atomic force microscopy and X-ray phase analysis. The fractal dimension was determined using the cube counting method. X-ray diffractometric analysis in the in situ measurement mode with discrete heating (in 100 °C increments) in air up to 1000 °C using the PAAR HTK-16 high-temperature attachment.Results. Using atomic force microscopy methods, it was found that the granulometric distribution of nanoclusters in the studied TaN nanofilms was Gaussian and an increase in the lateral size of particles was observed with an increase in the deposition time. The nanofilm with a deposition time of 300 s had minimal roughness. The statistical fractal dimension was calculated, the value of which corresponded to their three-dimensionality. According to the X-ray phase analysis data, the sizes of the coherence region, texturing, microdeformations and interplanar deformation distortions were determined, and a mixed Stranski-Krastanov mechanism of nanofilm formation was established.Conclusion. The surface roughness of nitride nanofilms formed at a constant power (500 W) depends significantly on the magnetron sputtering time and N2 concentration. In all studied nanofilm structures, the dominant growth mechanism was the mixed Stranski–Krastanov mechanism.

Single-Particle Crushing Test of Coated Calcareous Sand Based on MICP

Calcareous sand is a crucial construction material for island and reef development and reinforcing it using Microbially Induced Calcite Precipitation (MICP) technology is a promising new method. This study employed 3D scanning technology to assess changes in the particle size and morphology of MICP-treated, coated calcareous sand particles. Single-particle crushing tests were conducted to analyze their crushing strength, crushing energy, crushing modes, and fragment fractal dimensions. The results indicated that MICP treatment significantly increased particle size, surface area, and volume, while reducing flatness. At a cementation solution concentration of 1 mol/L, both crushing strength and crushing energy were optimized. The coated particles exhibited three crushing modes: explosive crushing, mixed crushing, and splitting crushing. Thicker coatings led to a tendency for particles to break into larger fragments through the mixed and splitting crushing modes. Fractal analysis revealed that coating thickness directly affects the local crushing characteristics of the particles.

Control of encapsulation efficiency and morphology of poly(lactide-co-glycolide) microparticles with a diafiltration-driven solvent extraction process

The removal of organic solvents during the preparation of biodegradable poly(D,L-lactide-co-glycolide) (PLGA) microparticles by an O/W- solvent extraction/evaporation process was investigated and controlled by diafiltration. Emulsification and steady replacement of the aqueous phase were performed in parallel in a single-vessel setup. During the process, the solidification of the dispersed phase (drug:PLGA:solvent droplets) into microparticles was monitored with video-microscopy and focused beam reflectance measurement (FBRM) and the residual solvent content was analyzed with headspace gas chromatography (organic solvent) and coulometric Karl-Fischer titration (water). Microparticles containing dexamethasone or risperidone were characterized with regard to particle size, morphology, encapsulation efficiency and in-vitro release. Diafiltration-accelerated solvent extraction shortened the process time by accelerating solidification of dispersed phase but reduced the residual dichloromethane content only in combination with increased temperature. Increasing the diafiltration rate increased particle size, porosity, and the encapsulation efficiency of risperidone. The latter effect was particularly evident with increasing lipophilicity of PLGA. A slower and more uniform solidification of end-capped and increased lactide content PLGA grade was identified as the reason for an increased drug leaching. Accelerated solvent extraction by diafiltration did not affect the in-vitro release of risperidone from different PLGA grades. The initial burst release of dexamethasone was increased by diafiltration when encapsulated in concentrations above the percolation threshold. Both porosity and burst release could be reduced by increasing the process temperature during diafiltration. Residual water content was established as an indicator for porosity and correlated with the burst release of dexamethasone.

A Three–Dimensional Nanoscale View of Electrocatalyst Degradation in Hydrogen Fuel Cells

AbstractThe loss of platinum (Pt) electrochemically active surface area (ECSA) is a critical degradation mode that often becomes a limiting factor for heavy‐duty proton exchange membrane fuel cell vehicles. High surface area carbon supports have been shown to improve Pt dispersion and limit detrimental ionomer‐electrocatalyst interactions due to their large interior pore volume. In this work, using automated scanning transmission electron tomography, the degradation of nanoparticles located on the interior versus exterior surfaces of the carbon support is compared following a catalyst‐specific accelerated stress test (AST) of 90,000 voltage cycles between 0.6 V to 0.95 V. The results reveal a notable increase in median particle size for both interior and exterior Pt catalyst particles, with a slightly higher increase in particle size distribution and loss of specific surface area for the particles located on the exterior carbon surface. The fraction of Pt nanoparticles that reside within the interior of the carbon support also increased following the AST test, accompanied by evidence of an increase in average carbon mesopore size. The results shed light on the degradation mechanisms affecting electrochemical properties and the enhanced particle accessibility at lower relative humidity.

Green synthesis, characterization, and multifunctional applications of Ag@CeO2 and Ag@CeO2-pullulan nanocomposites for dye degradation, antioxidant, and antifungal activities

The synthesis and characterization of novel nanocomposites with unique properties have garnered significant interest. Ag@CeO2 nanocomposite and its pullulan counterparts were prepared using a green approach involving rosemary extract. Characterization techniques, including Fourier Transform Infrared Spectroscopy, UV–visible spectroscopy, zeta potential, Dynamic Light Scattering, High-Resolution Transmission Electron Microscopy, Energy-Dispersive X-ray Spectroscopy, Scanning Electron Microscopy, and X-ray Diffraction, confirmed the formation of Ag@CeO2 nanoparticles (NPs). Pullulan led to increased particle size and improved homogeneity. Employing the Artificial Neural Networks (ANN) model to optimize methylene blue removal by Ag@CeO2 NPs and Ag@CeO2-pullulan NPs demonstrated predictive capabilities up to 97.53 % of MB removal (R2 = 0.9991). The antioxidant test demonstrated that rosemary extract exhibited the highest activity (IC50 = 0.011 mg/mL), then Ag@CeO2 NPs (IC50 = 0.039 mg/mL), and Ag@CeO2-pullulan NPs (IC50 = 0.041 mg/mL). Both Ag@CeO2 NPs and Ag@CeO2-pullulan NPs inhibited Candida albicans growth, with the latter exhibiting enhanced efficacy (MIC = 468.27, MFC = 936.53, and IC50 = 129.60 μg/mL). The study successfully synthesized novel Ag@CeO2-based nanocomposites coupled with pullulan with promising applications in dye removal, and antimicrobial therapy. The incorporation of pullulan improved the properties of the nanocomposites, enhancing their potential for practical use in environmental and biomedical applications.

Mechanism of sucrose improving the mechanical characteristics of foams stabilized by soy protein isolate/gellan gum/guar gum ternary complex

Sucrose shows the potential of stabilizing foam system. This study systematically evaluated the mechanism by which sucrose improved foaming properties and mechanical characteristics of foams stabilized by soy protein isolate/gellan gum/guar gum ternary complex. Results showed that sucrose could bond to the surface of ternary complex or self-aggregate within the continuous phase, resulting in the neutralization of charges (nearly zero) and an increase in particle size (up to 62.54 μm). The addition of 30 % sucrose reinforced foam system with an increased foamability (305.99 %) but a longer foaming time (10 min) during foaming process. Moreover, the mechanical characteristics, including hardness, elastic strength (Power-law constant) and solid characteristic (frequency exponent), were also significantly enhanced to 1.26 N, 354.7956 and 2.5873, respectively, which were 1.65, 1.94 and 1.11 times than those of foams without sucrose. The microscopic mechanism lied in the reduced water freedom degree caused by sucrose, which generated a compact structural network around bubbles for providing a stable and stiff structure to foams. These findings will provide clear theoretical guidance for regulating mechanical characteristics of aerated foods by using sucrose as structural building blocks.

Effect of WC particle size on the microstructural evolution and tribological properties of laser cladding Ti-bearing Co-based WC reinforced coating

To improve the wear resistance of 300 M steel under reciprocating wear in landing gear shock strut, Ti-bearing Co-based WC reinforced coatings with three different WC particle sizes (280 mesh, 200 mesh, and 150–300 mesh) were successfully fabricated by laser cladding method. The effect of WC particle size on phase composition, microstructure, microhardness and tribological properties were systematically investigated. The results show that the phase composition of these coatings consists mainly of γ-Co, TiC, WC, Cr23C6 and CrCo, and that varying the WC particle size changes the morphologies of the second phases. With the increase of WC particle size, the morphology of TiC is dendritic, ellipsoidal and block, respectively; the morphology of Cr23C6 changes from discontinuous fine particles to grid-like at grain boundaries. And the TiC-WC composite phases appear when the particle size of the added WC particles is a mixture. The coating with a mixture of 150–300 mesh WC particles, has the highest hardness range, the lowest average friction coefficient of 0.372, and the lowest wear rate of 9.61 × 10−5 mm3/N·m. The wear mechanisms of all three coatings are abrasive wear and oxidation wear, and the oxide film on the worn surface of the coatings gradually becomes denser and more continuous with increasing WC particle size.

Enhancing high‐temperature stability of limonene‐loaded nanostructured lipid carriers with various solid lipids

AbstractIn this research, nanostructured lipid carriers (NLCs) loaded with limonene were developed using various solid lipids. The impact of high temperatures on the characteristics of NLCs was investigated. NLCs exhibited zeta potential values exceeding |30| mV, indicating excellent homogeneity and stability. Increasing the carbon chain length of monoglycerides from C15 to C21 resulted in a corresponding increase in particle size of NLCs from 219.1 ± 1.1 to 243.3 ± 0.9 nm. However, the particle size remained relatively constant with an increase in the number of solid lipid carbon chains. Encapsulation efficiency of limonene increased from 66.0 ± 0.7% to 86.2 ± 0.8% with an increase in the number of solid lipid carbon chains. The result showed that more ester bonds facilitated the dissolution of the target and enhanced the interaction forces between solid lipids and the target. X‐ray diffraction, Fourier transform‐infra‐red spectroscopy and differential scanning calorimetry analyses confirmed effective encapsulation of limonene in NLCs, resulting in good stability. NLCs prepared from various solid lipids exhibited varying properties. Glycerol triglyceride demonstrated superior stability and homogeneity of nanoparticles under high‐temperature conditions compared to other solid lipids. This study provides enhancing the thermal stability of limonene‐loaded NLCs and proposes a novel approach for their practical application.

Facile co-precipitation synthesis of nano-molybdenum-doped BaO nanoparticles and their physical characterization

Alkaline metal oxides have received significant attention recently due to their abundance, inherent conductivity, optical absorption, and thermal stability. Here, a straightforward co-precipitation method was employed to obtain both undoped BaO and Mo-doped BaO nanoparticles. Various techniques were used to characterize the synthesized nanoparticles’ structural, Raman spectral, optical, thermal, and electrical properties. X-ray diffraction (XRD) results revealed that Mo was successfully doped into tetragonal nanocrystalline BaO. The W-H plot showed that as Mo doping increases from 2 % to 6 %, the crystallite size grows while the lattice structure remains well-ordered with even strain distribution. Scanning electron microscopy (SEM) was used to examine its surface features. The purity and crystalline character of the samples were further confirmed via Raman spectroscopy, which shows that the peak intensity of the spectra increases with the increase of particle size owing to the rise in the force constant. UV spectroscopy was used to observe the energy band gap, which is found to decrease from 4.2 eV to 3.8 eV, and then it drops to 3.4 eV as the Mo content increases. This is reasonable because of the size-dependent attraction between metallic ions and conduction electrons. PL spectra concluded that Mo doping leads to the enhancement of the optical characteristics of BaO. Adding Mo to BaO also modifies the material’s thermal properties, potentially affecting its suitability for applications that require thermal durability. This finding exhibits that even slight doping of Mo4+ into BaO can significantly impact their structural, thermal, optical, and electrical characteristics. It enriches the existing body of knowledge of BaO nanoparticles and lays the foundation for its future research.

The effect of carbon addition on the synthesis process and the physical/electrocatalytic properties of FeTiO3 nanopowder produced by solution combustion synthesis method

The FeTiO3 nanopowder is a vital engineering material known for its exceptional performance in energy generation, storage, electrochemical sensors, and catalysis. However, synthesizing FeTiO3 nanopowder with high crystallinity and phase purity typically requires specialized equipment and controlled heat treatment due to the instability of Fe2+ ions. Using the one-step solution combustion synthesis (SCS) method, FeTiO3 nanopowder withe high crystallinity were successfully produced utilizing basic equipment. Additionally, the influence of carbon additives on phase transitions, as well as the physical and physicochemical properties of the synthesized powder, was examined. XRD results indicate that increasing the amount of fuel, particularly glycine, creates a stable environment for the crystallization of FeTiO3 nanoparticles. Moreover, enhancing the carbon content in precursor solutions with urea enhances reduction conditions and boosts the stability of FeTiO3 in the final product. The presence of carbon additives in glycine-fuel samples leads to unfavorable outcomes by increasing the levels of TiO2 and Fe3O4 undesirable phases. Incorporating additive carbon into the urea-synthesized precursor solution resulted in a particle size increase exceeding 50 nm and raised the combustion temperature by a minimum of 230 °C. Furthermore, the presence of 15 wt% additive carbon in the sample synthesized with glycine improved the specific surface area of particles from 2.44 m2/g to 18.41 m2/g. Obtained results have shown that achieving high crystallinity of FeTiO3 nanopowder is feasible through a one-step solution combustion synthesis process. This can be accomplished by carefully choosing the synthesis conditions, such as the type and quantity of fuel, along with the carbon additive.

Investigate on spontaneous combustion characteristics of lignite stockpiles considering moisture and particle size effects

Coal spontaneous combustion (CSC) threatens the safety of the coal industry, with moisture content and particle size being pivotal factors. This study examines the heating dynamics and critical self-ignition temperatures (CSITs) of Baiyinhua lignite stockpiles through wire-mesh basket (WMB) tests at two scales. The CSC process in coal stockpiles unfolds in four stages. Notably, Stage II is notable for significant moisture evaporation between 43 and 84 °C, while Stage IV marks the onset of self-heating. Moisture evaporation absorbs heat, linearly prolonging the Stage II duration, which accounts for 0%–70 % of the total time. Conversely, larger particle sizes enhance pore seepage, effectively shortening the heating time. The time for d = 20 mm (particle size) coal sample to reach ambient temperature is roughly half that of 1.5 mm. CSITs of raw coal increase by 10–15 °C compared to the dry coal, and CSIT of coal samples with d = 50 mm has increased by 17.5 °C compared to 10 mm. Therefore, both an increase in particle size and moisture content increase the CSIT, thereby reducing the propensity for CSC. Frank-Kamenetskii theory and dimensionless analysis predict spontaneous combustion risks in field-scale coal stockpiles. This investigation contributes valuable insights to the estimation and prevention of CSC.

Elucidating the Hydrolysis and Polymerization Reactions of Al3+‐Solvated Molecules by Reactive Molecular Dynamics Simulation

ABSTRACTUtilizing the reactive molecular dynamics (ReaxFF MD) simulation, we conducted a comprehensive study on the impact of basicity (OH−/Al3+ ratio), concentration, and temperature on the hydrolysis and polymerization reactions of Al3+‐solvated molecules. Through simulations, we analyzed the structural changes, energy fluctuations of the system, and the evolution patterns of reaction products under different parameters, which were subsequently validated by experimental data. The research results indicate that hydroxide ions in the solution directly influence the breakage of OH bonds in the coordinating water molecules of solvated aluminum ions. This, in turn, affects the number of H2O and OH− ions coordinated with Al3+, leading to changes in hydrolysis products. Additionally, the number of OH− ions surrounding Al3+ affects the electrostatic repulsion, making it easier for polymerization reactions to occur as the system approaches the point of zero charge. On the other hand, an increase in concentration and temperature enhances the frequency of cluster collisions, thus contributing to an increase in polymerization degree. The experimental results align closely with our simulated predictions. As the pH value increases, the particle size exhibits a trend of first increasing and then decreasing, reaching a maximum at the point of zero charge. Simultaneously, an increase in concentration also prompts an increase in particle size. The combination of these empirical results with simulations enhances the credibility and reliability of our model's predictive capabilities. This study not only expands our understanding of the relevant chemical reaction processes but also provides important theoretical support for practical applications in related fields.

A maghemite (γ-Fe2O3) incorporated activated carbon photocatalytic nanocomposite fabricated via Co-precipitation utilized against degradation of methyl orange

The γ−Fe2O3/ACP has been synthesized in different ratios by facile co-precipitation method to degrade the methyl orange dye. In order to check the stability and potential of photo activated catalyst, UV, PL, SEM, XRD, EDX, FTIR and Zeta Potential are discussed here. The bandgap has been reduced from 2.06 eV to 1.86eV. Here, 1:3 γ−Fe2O3/ACP sample showed maximum reduced bandgap of 1.86 eV. The PL spectroscopy showed that 1:3 sample has less intensity, which in turn have 94 % photo degradation of methyl orange dye in 180min. The 1:3 sample showed 87 % degradation of methyl blue dye at 125mins light irradiation and proved as an optimal concentration of ACP in maghemite at pH of 11. The inclusion of carbon into maghemite enhances the overall properties by reducing the charge recombination rate. No impurity has been found in the final synthesized samples confirmed through EDX. The XRD and SEM revealed that size of crystallites and particle size increases, which confirms that bandgap is reduced. While trapping techniques and recycling techniques has been employed on the optimal concentration sample to check its stability towards degradation of methyl orange (MO) dye. The photo catalysis through such nanocomposite is not reported before. The 1:3 sample showed promising potential towards pollutants degradation in waste water treatment.

Effects of solutes and additives on ice growth prevention in ice slurry production

Ice slurry is a promising functional fluid with high thermal energy density and high heat transfer rate. However, large ice particles in the ice slurry can cause blocking of tubes during ice slurry flow. Therefore, it is preferable to use fine ice particles to prepare ice slurry in many fields. In this study, ice slurries were generated from supercooled solutions containing additives, such as anti-freeze protein and polyvinyl alcohol, to prevent the increase in the ice particle size in the formation process of the ice slurry. The concentration of the solute and amount of the additive were varied as experimental parameters, and the size of the ice particles was evaluated. The average area of the ice particles decreased with the addition of the additives. In particular, anti-freeze protein was effective for generating fine ice particles in the ice slurry. However, the effects of the additives became weaker for higher concentration of the solute, and the size of the ice particles was almost the same regardless of the concentration of the solute and the amount of the additive. Moreover, it was found that particular properties, such as the freezing-point depression, kinematic viscosity of the solution, and effective latent heat of fusion, did not affect the size of the ice particles in the ice slurry generation process.

D-arginine-functionalized carbon dots with enhanced near-infrared emission and prolonged metabolism time for tumor fluorescent-guided photothermal therapy

Carbon dots (CDs) have garnered significant interest owing to their distinctive optical properties. However, their bioimaging and biomedical applications are limited by pronounced fluorescence (FL) quenching in aqueous media and low tumor accumulation efficacy associated with their ultra-small size. This study proposes a simple surface modification approach using functioning d-arginine on CDs (d-Arg@CDs) to improve their near-infrared (NIR) FL in aqueous solution and maintain their high photothermal conversion properties. Because of the low utilization rate of dextral amino acids in animals, modifying CDs with low molecular weight d-arginine did not increase particle size but extended the metabolism time in blood circulation, thereby leading to enhanced accumulation efficacy at tumor sites in the mice model. The enhanced tumor accumulation of d-Arg@CDs resulted in significantly superior tumor NIR FL imaging and photothermal therapy performance compared with pure CDs and l-arginine functionalized CDs. This dextral amino acid modification approach is expected to be an effective tool for enhancing the biomedical applications of CDs.

High-temperature deposition model for molten particle prediction based on droplet-surface interaction criteria

Particle deposition in gas turbine engines damages blade surfaces and diminishes engine performance. Deposition results from heat and momentum exchanges between fluid and particles, coupled with the interactions between particles and surfaces. The increasing turbine inlet temperatures cause particles to become molten, complicating their interaction with surfaces. Existing models fail to convincingly explain the deposition behaviors of molten particles. In the present study, considering particle fluidity and the nonlinear accumulation of deposits, the deposition criteria for viscous droplets and the maximum steady deposit layer model were incorporated to establish an unsteady high-temperature deposition model. The new model, validated against experiment results in the literatures, predicts molten particle deposition behavior with an average error of 3.89 % in capture efficiency at high-temperature conditions. It accurately predicts crown-like deposit morphology and nonlinear accumulation, matching experimental observations. Applied to nozzle guide vanes with film cooling, results show that deposits primarily occur on the leading edge and pressure side near the trailing edge. The particle capture efficiency initially rises before diminishing as particle size increases, whereas an inverse trend is noted with the escalation of the mass flow ratio. At a mass flow ratio of 0.15, the capture efficiency hits the minimum of about 13.2 %.

The angle of repose and base stress distribution of granular piles: An experimental investigation

The angle of repose and characteristics of the base stress distribution underneath granular piles serve as essential indicators in understanding the mechanical and packing properties of particle system. One counterintuitive phenomenon is that there is an evident dip of the base stress beneath the pile apex that might have implications in the design of granular pile facilities. The repose angle and stress dip are influenced by many categories of factors and exhibit different variations. Based on the localized source method, particle packing experiments were conducted to investigate the effects of funnel height, particle size, particle shape, and packing method on the repose angle and the vertical stress distribution of granular piles. The experimental results show that the repose angle of piles of irregular particle shape and higher funnel height is much larger, but there is a decreasing trend of repose angle with increasing particle sizes. The natural packing angles before and after the critical collapse of granular pile exhibits periodic variation. On the other hand, the stress dip phenomenon occurred in all granular piles constructed by localized procedure. An increase in funnel height and a middle particle size mitigate the stress dip to some extent, whereas irregular particle shape exacerbates it. Comparison of the results from different packing methods reveals that larger repose angle and more pronounced stress dip are observed in confined packing piles compared to that in free packing piles. Considering a growth rate of less than 5 %, the average vertical stress under the sand silo reaches saturation state. Moreover, the pressure on the silo wall increases with the height of silo pile but remains somewhat lower than predicted by the Ketchum equation and current design values.

The increase of particle size shifts the biogeochemical cycle functions of mineral-associated microorganisms and weakens the mineral-associated organic carbon sink in mangrove soils.

Carbon with stable forms, such as mineral-associated organic carbon (MOC), is crucial for the sink capabilities in mangrove soils, and mineral-associated microorganisms (MMOs) are important players for the formation and metabolism of MOC. Therefore, the future successions of the MMO functions and MOC contents under the background of climate change are of value for a deeper understanding of mangrove ecology. The relative sea level rise caused by the global warming results in the increase of mangrove soil particle size (PS), which provides distinct microcosms for MMOs and MOC. However, the responses of MMO functions and MOC content to the PS increase of mangrove soils are unknown. The current study aims to reveal the succession regulations of MMO functions and their potential ecological impacts for the storages of MOC in different PS fractions, therefore widening our knowledge of future function migration and promoting the research development of mangrove.

Numerical Simulation of CO Generation and Combustion Efficiency in Sintering Process: Effect of Solid Fuel Particle Size

For sintering pot productive process with various fuel particle size distributions, a transient numerical simulation sintering model based on the computational fluid dynamics approach is developed using Fluent 2021R1. The model combines chemical reaction, mass and heat transfer, Euler–Euler model, and fluid flow in porous media. In this study, CO is employed as the combustion's intermediate product, which is further oxidized by secondary combustion in the high‐temperature zone. Through calculations, the solid fuel combustion behavior of the sintering is explained collectively with the changing bed temperature, CO emission, and solid fuel combustion efficiency of the process under various fuel particle size distribution. In the sintering process, the fuel particle size distribution is crucial for lowering CO emissions and increasing combustion efficiency. The combustion efficiency shows a tendency of increasing initially before decreasing with the reduction of solid fuel particle size, while CO emissions show a trend of reducing first and then increasing. It is advantageous to lower the CO emission in the sintering process, and the combustion efficiency of the sintering process is greatly boosted by 5.13% when the proportion of solid fuel with 5 mm particle size decreases and the proportion of solid fuel with 3 mm particle size increases.

Impact of Particle Size on the Physicochemical, Functional, and In Vitro Digestibility Properties of Fava Bean Flour and Bread.

Fava beans, renowned for their nutritional value and sustainable cultivation, are pivotal in various food applications. This study examined the implications of varying the particle size on the functional, physicochemical, and in vitro digestibility properties of fava bean flour. Fava bean was milled into 0.14, 0.50, and 1.0 mm particle sizes using a Ferkar multipurpose knife mill. Physicochemical analyses showed that the 0.14 mm flour had more starch damage, but higher protein and fat contents. Functionality assessments revealed that the finer particle sizes had better foaming properties, swelling power, and gelation behavior than the coarse particle size. Emulsion capacity showed that for all the pH conditions, 1.00 mm particle size flour had a significantly higher (p < 0.05) oil droplet size, while the 0.5 and 0.14 mm flours had smaller and similar oil droplet sizes. Moreover, in vitro digestibility assays resulted in improved starch digestion (p ˂ 0.05) with the increase in flour particle size. Varying the particle size of fava bean flour had less impact on the in vitro digestibility of the bread produced from wheat-fava bean composite flour, with an average of 84%. The findings underscore the critical role of particle size in tailoring fava bean flour for specific culinary purposes and nutritional considerations.