Micron-sized Powders Research Articles

Development of an epoxy-metallic powder sublayer for the cold spray metallization of carbon-fiber reinforced thermoset composites

This paper investigates the development of a composite sublayer for the cold spray metallization of carbon-fiber reinforced thermoset composites. The hybrid sublayer/carbon-fiber reinforced structure is prepared using a vacuum assisted infusion process. The sublayer consists of a mixture of epoxy with micron-sized metallic powder particles and is directly embedded onto the carbon-fiber reinforced structure during the infusion process. During the cold spray metallization, the erosion of this biphasic sublayer has the capability to produce a metal-to-metal bonding between the cold sprayed powder particles and the sublayer powder particles. The mechanical response of the sublayer due to the high-speed collision of the cold spray powder is investigated using a computational analysis. A decohesion at the epoxy/metallic particle interface within the sublayer, along with the fragmentation of the epoxy matrix upon impact, eases an erosion that prevents the coating formation onto the sublayer. The erosion/coating formation strongly depends on the mechanical property of the spray powder compared to the powder of the sublayer. In the case of a sublayer made of soft metal particles, the plastic deformation during the high-speed collision is better absorbed by such a biphasic sublayer. This circumstance is conducive to an adhesion of the sprayed particles onto the sublayer despite an occurrence of an erosion. Thus, the cold spray deposition of Cu powder onto a biphasic epoxy/Al sublayer results in deposit formation, with Cu particles bonding to Al particles and anchoring to the epoxy matrix.

Role of the Magnus effect in additive manufacturing at the scale of the micron-sized powders within the supersonic gas flow of cold spraying.

Role of the Magnus effect in additive manufacturing at the scale of the micron-sized powders within the supersonic gas flow of cold spraying.

Anti-icing and de-icing properties of composite superhydrophobic coating with microwave heating performance on asphalt pavement

Severe icing on asphalt pavements significantly impacts traffic safety and efficiency. Superhydrophobic coatings exhibit excellent hydrophobic and anti-icing properties, making them suitable for asphalt pavements. However, the formation of dense and hard ice limits their anti-icing effectiveness in cold regions. Within this paper, we have developed a novel composite superhydrophobic coating (CSC) with microwave heating performance by constructing a hierarchical structure using carbon nanotubes and incorporating micron-sized iron powder as a primary microwave-absorbing material. Scanning electron microscopy, 3D confocal microscopy, and contact angle tests reveal that the optimally mixed CSC possesses a complex micro-nano hierarchical structure, superhydrophobic properties (contact angle of 155.4°), and excellent anti-icing properties. Microwave heating results show that the CSC achieves a maximum heating rate of 1.108 ℃/s and an energy utilization efficiency of 47 %, representing improvements of 118.1 % and 18.3 % compared to uncoated specimens. Durability tests indicate that after wear, the CSC's contact angle decreases by 6.2 %, and the microwave heating rate drops by 13.7 %. Despite these reductions, the coating still maintains high hydrophobicity and microwave heating performance. While the friction coefficient of CSC-coated pavement decreases to μ=0.63, it still meets regulatory requirements. Overall, the application of CSC can effectively increase de-icing efficiency and mitigate the adverse effects of ice and snow on pavements.

Preparation of CIP@Fe3O4 particles and their impact on the fenton reaction processing performance of single-crystal SiC

This study proposes the preparation of CIP@Fe3O4 composite magnetic particles, which maintain excellent magnetic properties while exhibiting superior Fenton reaction performance for the magnetorheological chemical polishing of single-crystal SiC. The CIP@Fe3O4 particles were prepared by coating a nanoscale layer of Fe3O4 onto micron-sized carbonyl iron powder (CIP) using the co-precipitation method. Their Fenton reaction performance and magnetic properties were characterized, and CIP@Fe3O4 was used as a solid-phase catalyst in Fenton reaction-induced etching, frictional wear, and polishing experiments on single-crystal SiC. The prepared CIP@Fe3O4 particles have a saturation magnetization of 184.3 emu/g, representing only an 8.7 % reduction compared to CIP, yet achieved a decolorization rate of 76.2 % for the methyl orange indicator (compared to only 17.2 % with CIP alone). The Fenton reaction using CIP@Fe3O4 resulted in a prominent corrosion layer on the surface of single-crystal SiC, with the oxygen atomic fraction reaching 22.15 %. The study examined material removal from SiC under Fenton reactions with different solid-phase catalysts: CIP, CIP@Fe3O4, and CIP + Fe3O4. Frictional wear results indicated that the maximum scratch cross-sectional removal area on the SiC surface under the Fenton reaction with CIP@Fe3O4 was 474.38 μm2, representing a 207.3 % increase compared to without the Fenton reaction. Additionally, Si-O compounds were identified in the debris. Polishing experiments showed that the material removal rate (MRR) with the Fenton reaction was 3295 nm/h, an increase of 220.2 % compared to without the Fenton reaction, and the surface roughness was reduced to Ra 0.895 nm, a 73.4 % reduction compared to without the Fenton reaction. This study provides additional evidence for the application of magnetorheological technology and the Fenton reaction in the polishing field of single-crystal SiC.

Temperature-irrelevant superhydrophobic polyimide–SiO2 aerogels with a confined shrinkage strategy for high-temperature thermal protection (>400 °C)

Polyimide (PI) aerogels often experience substantial volume shrinkage when exposed to temperatures above 200 °C. Furthermore, research regarding the hydrophobic characteristics of PI aerogels under high-temperature conditions is limited. Herein, a confined shrinkage strategy was proposed, and the PI–SiO2 aerogels were prepared with ultralow thermal shrinkage and high-temperature superhydrophobic properties. Micrometer-sized silica aerogel powders were used in this strategy as shrinkage inhibitors during the production of PI aerogels. The silica aerogel powders were then pulled together using the PI chain and braced to each other, limiting the shrinkage of the PI aerogel matrix attached to the powders. Results indicated that the prepared aerogel experienced a shrinkage of only 6.2 % after heat treatment at 400 °C for 1 h in a muffle furnace. The surface area of the sample decreased from 669 m2/g to 649 m2/g after heat treatment, revealing a reduction of only 2.7 %. Previous studies have never reported this remarkable thermal stability. Furthermore, the aerogel exhibited superhydrophobic properties with a water contact angle of 157.4° and a water rolling angle of approximately 0° at 300 °C due to its high surface roughness.

Hierarchically Porous Structured Adsorbents with Ultrahigh Metal-Organic Framework Loading for CO2 Capture.

Metal-organic frameworks (MOFs) have emerged as promising candidates for CO2 adsorption due to their ultrahigh-specific surface area and highly tunable pore-surface properties. However, their large-scale application is hindered by processing issues associated with their microcrystalline powder nature, such as dustiness, pressure drop, and poor mass transfer within packed beds. To address these challenges, shaping/structuring micron-sized polycrystalline MOF powders into millimeter-sized structured forms while preserving porosity and functionality represents an effective yet challenging approach. In this study, a facile and versatile strategy was employed to integrate moisture-stable and scalable microcrystalline MOFs (UiO-66 and ZIF-8) into a poly(acrylonitrile) matrix to fabricate readily processable, millimeter-sized hierarchically porous structured adsorbents with ultrahigh MOF loadings (∼90 wt %) for direct industrial carbon capture applications. These structured composite beads retained the physicochemical properties and separation performance of the pristine MOF crystal particles. Structured UiO-66 and ZIF-8 exhibited high specific surface areas of 1130 m2 g-1 and 1431 m2 g-1, respectively. The structured UiO-66 achieved a CO2 adsorption capacity of 2.0 mmol g-1 at 1 bar and a dynamic CO2/N2 selectivity of 17 for a CO2/N2 gas mixture with a 15/85 volume ratio at 25 °C. Furthermore, the structured adsorbents exhibited excellent cyclability in static and dynamic CO2 adsorption studies, making them promising candidates for practical application.

Synthesis of uniform spherical silver powder without dispersants in a confined impinging-jet reactor

Sliver powder is the most common and extensively utilized precious metal powder in electronics, primarily for electronic paste. Herein, micron-sized spherical silver powder was synthesized via a liquid phase reduction method employing silver nitrate as the source of silver and ascorbic acid as the reducing agent in a confined impinging jet reactor (CIJR). The impact of the molar ratio between silver nitrate and ascorbic acid, the flow rate, and the temperature on the particle size of silver powder was investigated. The optimal process conditions for silver powder are as follows: maintain a molar ratio of 1:1 and control the feeding rate at 10 ml/min while operating at 50 ° C. The confined impinging jet reactor offers enhanced control over reaction conditions during the synthesis of silver powder, surpassing the capabilities of traditional batch reactors. The aforementioned optimized methodology was employed to successfully synthesize uniform and spherical silver powder (with an aspect ratio approaching 1) in the low Reynolds number jet, resulting in an average particle size of d50 = 0.83 μm and a standard deviation of 0.07, without the addition of dispersant. The synthesis method presented here improves the performance of silver powder, simplifies the production process, reduces energy consumption, and minimizes waste generation. These advances yield significant environmental and economic benefits. In the future, with the continuous development and optimization of microreactor technology, this synthesis method is anticipated to play a more prominent role in the commercial-scale production and application of micrometer-sized silver powder.

Chemical strengthening of glass powder particles

It is well known that chemical strengthening of glass brings the benefit of increased fracture strength. Despite extensive research on processing and mechanics at the macroscale, the effectiveness of chemical strengthening on glass elements with all three dimensions in the micrometer regime remains largely unexplored. Here, we develop a novel process for chemical strengthening of micrometer-sized spherical glass powder particles and study the fracture behavior of these particles with in-situ particle compression tests inside a scanning electron microscope. Cross-sectional microscopy and energy dispersive spectroscopy measurements confirm ion exchange and show an increase in diffusion depth with an increase in processing time and temperature. We report a higher fracture strength for chemically strengthened powder particles compared with the as-received ones. We show that the increase in fracture strength is associated to the compressive residual stress resulting from ion exchange during chemical strengthening.

Achieving high strength and ductility in Inconel 718: tailoring grain structure through micron-sized carbide additives in PBF-LB/M additive manufacturing

ABSTRACT Few attempts have been made so far to develop modifiers for in situ use in Inconel 718 PBF-LB/M fabrication. Reports show an increase in tensile strength compared to unmodified counterparts. However, significant ductility reduction is observed, outweighing the mere tensile strength improvements when considering practical applications. In this study, micron-sized powder modifiers (NbC, TiC, and B4C) were added in proportions of 0.6 wt.% (NbC and TiC) and 0.2 wt.% (B4C) to Inconel 718 powder for PBF-LB/M processing. These modifiers allowed for grain structure control during heat treatment, including hot isostatic pressing. The addition of NbC resulted in a finer grain structure, while the addition of TiC preserved the as-built grain structure after heat treatment. Carbide precipitates led to uniform GND distribution and promoted uniform stress distribution. We show that the trade-off between strength and ductility in carbide-modified IN718 can be overcome by careful PBF-LB/M processing and heat treatment.

Rheological Behavior of SiO2 Ceramic Slurry in Stereolithography and Its Prediction Model Based on POA-DELM.

Ceramic slurry is the raw material used in stereolithography, and its performance determines the printing quality. Rheological behavior, one of the most important physical factors in stereolithography, is critical in ceramic printing, significantly affecting the flow, spreading, and printing processes. The rheological behavior of SiO2 slurry used in stereolithography technology is investigated in the current research using different powder diameters and temperatures. The results present the apparent non-Newtonian behavior. The yielding characteristics occur in all cases. For single-powder cases, the viscosity decreases when the powder diameter is increased. When the nano-sized and micro-sized powders are mixed in different proportions, a more significant proportion of micron-sized powders will decrease the viscosity. With an increase in the nano-sized powders, the slurry exhibits the shear thinning behavior; otherwise, the shear thickening behavior is observed. Thus, the prediction model is built based on the use of the pelican optimization algorithm-deep extreme learning machine (POA-DELM), and the model in then compared with the fitted and traditional models to validate the effectiveness of the method. A more accurate viscosity prediction model will contribute to better fluid dynamic simulation in future work.

Graphene powders as new contact nanopesticides: Revealing key parameters on their insecticidal activity for stored product insects

The overuse and reliance on pesticides has caused insects to develop resistance with global concerns. To address this problem extensive research is directed to find new and sustainable alternatives using chemical-free and resistance-free solutions for pest control. This paper presents a comprehensive investigation of the insecticidal properties of several types of industrially produced graphene powder materials such as graphene and graphene oxide (GO) with micro- and nano size and different structural and chemical properties as new contact nanopesticides against three major stored grain insects: the rice weevil Sitophilus oryzae (L.), the lesser grain borer, Rhyzopertha dominica (F.)˙ and the larger grain borer, Prostephanus truncatus Horn. Bioassays were performed using different concentrations, i.e., 0, 100, 500 and 1000 ppm of graphene powders on the mortality of selected adult insects recorded after 3, 7, 14, and 21 days of exposure and progeny production after 65 days. Results showed that graphene oxide (GO) has no insecticidal efficacy while graphene powders with nano-size particles showed significantly enhanced insecticidal performance compared to micron-size graphene powders. The observed insecticidal effects are explained by the higher probability that nano-sized graphene particles adhere on the insect body compared to large particles. The mortality is proposed as the result of physical mode of action of attached graphene nanoparticles causing stronger interruption of the protective cuticle layer, gas respiratory functions and faster mortality. The findings of this study revealed that it is important to select graphene materials with optimal structural and interfacial properties to achieve the highest insecticidal performance in potential development of a new generation of sustainable insecticides.

Synthesis of Mesoporous Tetragonal ZrO2, TiO2 and Solid Solutions and Effect of Colloidal Silica on Porosity.

Metal oxides possessing a large surface area, pore volume and desirable pore size provide more varieties and active industrial potentials. Nevertheless, it is very challenging to produce crystal metal oxides while keeping satisfactory porosity features, especially for ternary compositions. High temperature is usually needed to produce crystal metal oxides, which readily leads to the collapse of the pore structure. Herein, by employing a 'soft' dispersant agent and a hard silica template, ZrO2, TiO2 and Zr-Ti solid solutions having a tetragonal crystal structure are produced and the silica-leached materials are characterized from macroscopic to atomistic scales. The micron-sized particulate powders are composed of nanoscale 'building blocks', with crystallite sizes between ~8 and 21 nm. These polycrystalline ceramic powders exhibit a high specific surface area (up to ~200 m2·g-1) and pore volume (up to 0.5 cm3·g-1), with a pore size range of ~5-20 nm. Importantly, the Zr/Ti-O-Si-OH chemical bonds exist on the particle surface, with about two-thirds of the surface covered by silica. The hydroxyl groups can further post-graft organic ligands or directly associate with species. Synthesized mesoporous metal oxides are highly homogenous and could potentially be used in various applications because of their tetragonal structure and porosity features.

Thermal plasma synthesis of Si-multi walled carbon nanotube nanocomposite as an anode for lithium-ion batteries

The Si-MWCNT (multi-walled carbon nanotube) nanocomposite, which is considered a promising replacement for graphite as an anode material for lithium-ion batteries, was prepared using a triple DC thermal plasma jet system. We used micron-size silicon powder and MWCNT powder as raw materials. We varied the main parameters by mixing silicon and MWCNTs or individually injected into the plasma jet and adjusting the mass ratio to 2:1 and 1:2. The location of injection for the raw materials played a critical role in the formation of Si-MWCNT nanocomposites as the temperature at the injection site has a significant impact on the vaporization of silicon and sublimation of carbon nanotubes. Additionally, it was influenced by efficient heat transfer of silicon and the structural change of MWCNT. As a result, the Si-MWCNT nanocomposite was easily produced under separate injection conditions, and silicon nanoparticles of 20 nm or less were attached to the surface of the MWCNT. We evaluated the electrochemical performance of the synthesized material by assembling a CR2032-type coin cell using it as an anode electrode material.

Iron as Recyclable Metal Fuel: Unraveling Oxidation Behavior and Cyclization Effects Through Thermogravimetric Analysis, Wide-Angle X-ray Scattering and Mössbauer Spectroscopy.

The carbon-free chemical storage and release of renewable energy is an important task to drastically reduce CO2 emissions. The high specific energy density of iron and its recyclability makes it a promising storage material. Energy release by oxidation with air can be realized by the combustion of micron-sized iron powders in retro-fitted coal fired power plants and in fixed-bed reactors under milder conditions. An experimental parameter study of iron powder oxidation with air was conducted based on thermogravimetric analysis in combination with wide-angle X-ray scattering and Mössbauer spectroscopy. In agreement with literature the oxidation was found to consist of a very fast initial oxidation of the outer particle layer followed by much slower oxidation due to diffusion of iron ions through the Fe2O3/Fe3O4 layer being the rate-limiting step. Scanning electron microscopy analysis of the iron particle before and after oxidation reveal a strong particle morphology transformation. This impact on the reaction was studied by cyclization experiments. Up to 10 oxidation-reduction cycles show that both, oxidation and reduction rates, increase strongly with cycling due to increased porosity.

Tuning the rheological properties of paraffin-wax ceramic feedstocks for deposition with thermoplastic 3D printing

Droplet deposition with material-jetting methods such as thermoplastic 3D printing (T3DP) depends greatly on the rheological properties of the feedstocks. This study investigated the effect of particle interactions and the degree of weak flocculation on the shear thinning behaviour, the yield stress and the storage/loss moduli of paraffin-wax-based feedstocks containing 40 vol% of zirconia (3Y-TZP) micron-sized powder. Steric stabilization of the feedstocks was provided by varying the ratios of the surfactants with different chain lengths, i.e., stearic acid (2.4 nm) and Solsperse 3000® (10 nm), which in turn affected the dynamics of the droplet formation and the quality of the layers when jetting non-Newtonian, thermoplastic ceramic feedstocks. The results of the study extend the guidelines for the processing of printable feedstocks used in T3DP additive manufacturing.

A practical approach to fabrication of nano-Al2O3 reinforced MMC coatings by cold spray: Characterization of nanomechanical and tribological performance

Cold spray is a crucial solid-state deposition technique involving high-speed spraying of different-sized particles onto a base material. In this study, Ni-based powder reinforced with different proportions of nano-Al2O3 particles was sprayed onto Al6061 alloy by cold spray to improve the coating performance. Nanoparticles are very difficult to deposition as they are affected by the aerodynamic forces generated during cold spraying. With a practical approach, nanoparticles were agglomerated with micron-sized feedstock powders, and nanoparticles in the sprayed powder acted as larger particles and successfully defeated the aerodynamic force. The effects of adding nano-particles on the microstructural, nanomechanical, and tribological properties were investigated. Microstructural analyses revealed that MMC coating layers comprised ceramic particles and metal matrix (Ni and Zn). Due to the high spraying speed, the nano-particles were spread in the relatively ductile matrix formed by Ni and Zn. The micro- and nanohardness values were increased with nanoparticle volume by two mechanisms. In the first mechanism, the hard particle volume increased with the addition of nano powders, and in the second mechanism, the plastic deformation of the matrix increased due to the nano-particles. The sample without nanoparticle reinforcement exhibited plastic deformation during the initial stage of the nanoscratch test. The dry sliding wear test results showed that the nano-Al2O3-reinforced spraying powders increased the wear resistance approximately 1.9 times. According to FESEM and EDS examinations of worn surfaces and WC counter-bodies, nano-particles reduced the transferred layers caused by adhesion to the abrasive counter-body. In addition, the nano-particles were provided a more homogeneous hard particle distribution and improved wear performance.

Experimental investigation on synergistic slow oxidation and rapid combustion of micron-sized iron and aluminum powders for energy storage application

The investigation into the individual application of iron and aluminum as carbon-free fuel sources has been extensively explored and holds significant promise. However, there remains a gap in understanding synergistic effects achievable through the blending of these two fuels, as well as a need for comparative analyses between the slow oxidation and rapid combustion processes of these fuels to complement each other. This research proposes blending micron aluminum and iron powders to analyze their slow oxidation and rapid combustion features under diverse atmospheric conditions and heating rates, using thermogravimetric methods, kinetic calculations, and in-flow experiments. The research blending micron iron and aluminum powders to analyze their slow oxidation and rapid combustion features under diverse atmospheric conditions and heating rates, using thermogravimetric methods, kinetic calculations, and in-flow experiments. The findings reveal that the combination of aluminum and iron powders promotes oxidation, resulting in increased weight gain and heat flux rate compared to individual metals. Moreover, the triggering temperature rises from 545 to 652 °C with an increase in aluminum powder content. As heating rates increase, characteristic parameters T1, T2, and Hpeak2, rise for both fuels. However, aluminum powder tends to decrease Ti, while iron powder slightly increases it due to differences in oxide layers. The slow oxidation of aluminum and iron powders conforms to different models, yielding distinct oxidation patterns. The apparent activation energy of aluminum decreases from 258.4 to 238.7 kJ·mol−1 with rising heating rates, while that of iron exhibits a lower increase and remains lower than aluminum providing insights into combustion initiation conditions. Combustion initiation is contingent upon the concentration of metal powder and oxygen, with both aluminum and iron powders combustion being enhanced and subsequently attenuated with increasing excess air ratio. However, due to differing reactivity and surface passivation layers, the excess air ratio required for aluminum powder combustion (1.2–2.4) exceeds that of iron powder (1.3–1.7). The research elucidates the mechanisms underlying the slow oxidation of iron and aluminum fuels, delineates suitable combustion conditions, and furnishes new empirical and theoretical underpinnings for the oxidation characteristics of mixed iron-aluminum fuels, thereby advancing metal-fueled energy storage technologies.

Construction and toughening mechanism of B4C@TiB2 core–shell structural units inside the SiC ceramic

Core–shell structural B4C@TiB2 composite powders were synthesized via the molten salt method using micron-sized B4C and TiH2 powders as raw materials. Furthermore, a SiC composite ceramic with B4C@TiB2 core–shell structural units as the toughening phase was prepared by spark plasma sintering using SiC powder and the obtained B4C@TiB2 composite powder as starting powders. The effects of calcination temperature and raw material ratio on the phase compositions and microstructure of the B4C@TiB2 composite powders were studied, and the synthesis mechanism of the B4C@TiB2 composite powder was explored. The formation mechanism of B4C@TiB2 core–shell toughening units inside the SiC matrix was investigated, and the toughening mechanism of the SiC–B4C@TiB2 composite ceramic was discussed. Results show that the B4C@TiB2 core–shell units in the SiC matrix can induce a complex crack propagation mode and consume abundant crack propagation energy. Therefore, a high fracture toughness of 6.47 ± 0.32 MPa m1/2 is realized for the SiC–B4C@TiB2 composite ceramics.

Study on a Strong Polymer Gel by the Addition of Micron Graphite Oxide Powder and Its Plugging of Fracture.

It is difficult to plug the fracture water channeling of a fractured low-permeability reservoir during water flooding by using the conventional acrylamide polymer gel due to its weak mechanical properties. For this problem, micron graphite powder is added to enhance the comprehensive properties of the acrylamide polymer gel, which can improve the plugging effect of fracture water channeling. The chemical principle of this process is that the hydroxyl and carboxyl groups of the layered micron graphite powder can undergo physicochemical interactions with the amide groups of the polyacrylamide molecule chain. As a rigid structure, the graphite powder can support the flexible skeleton of the original polyacrylamide molecule chain. Through the synergy of the rigid and flexible structures, the viscoelasticity, thermal stability, tensile performance, and plugging ability of the new-type gel can be significantly enhanced. Compared with a single acrylamide gel, after adding 3000 mg/L of micrometer-sized graphite powder, the elastic modulus, the viscous modulus, the phase transition temperature, the breakthrough pressure gradient, the elongation at break, and the tensile stress of the acrylamide gel are all greatly improved. After adding the graphite powder to the polyacrylamide gel, the fracture water channeling can be effectively plugged. The characteristics of the networked water flow channel are obvious during the injected water break through the gel in the fracture. The breakthrough pressure of water flooding is high. The experimental results are an attempt to develop a new gel material for the water plugging of a fractured low-permeability reservoir.

Hydrothermal synthesis of regular and flaky gold particles for printed electronics

In this study, the gold precursors were rapidly reduced by hydroxy compound and micron-sized flaky gold powder was obtained under hydrothermal conditions. Isopropyl alcohol was selected as solvent and reducing agent after investigating the effect of reducing agent on the morphology of the gold powder. The influence of reaction concentration and temperature on the particle size and morphology of gold powder were researched. By controlling the reaction concentration and temperature, the prepared gold particles have regular flaky structure with the diameter of about 5 μm and the sintered gold conductor paste shows excellent conductivity and sintering density.