Powders, Volume 1, Issue 4 (December 2022) – 7 articles

Powder manufacturing processes involve a systematic processing of particulate material towards forming a final product which needs to meet specific quality standards. A means towards ensuring that standards are met in a manufacturing plant is to apply self-regulating intelligent machinery that can take mitigatory actions in the presence of a process deviation or unsatisfactory process behavior. Given a case study of an open-loop batch powder agglomeration process, this work synthesizes the process of how a feedback element can be applied towards the powder manufacturing plant in order to allow for self-regulation and process optimization which, in turn, would increase process efficiency, minimize waste and ensure that the overall product quality meets production targets. Focusing on a proposed cybernetic loop with a feedback element, a vital component is the ability to measure key quality attributes of the powder mixture, which is crucial towards ensuring the control algorithm is able to implement the most reflective and appropriate control strategy on the powder process; thus, this work discusses heavily the sensing and associated signal processing component of the cybernetic loop. The results from the reviewed signal processing scenarios which comprised the in-process material spanned estimation accuracies of 3–10%, depending on the scenario that was considered. This paper also addresses the feared dystopian view of mass redundancy and job losses in the age of the introduction of enhanced automation technology within a manufacturing process, where it is distilled what kinds of knock-on effects can be expected as a result of the technology, in addition to means by which policy makers can contribute towards ensuring that the adaptation and transition process is as smooth as possible. Full article

This paper investigates a current challenge that enables the hybridization of different materials using a solid-state additive principle. We investigate the suitability of such a principle to easily and efficiently grow a metallic electrically conductive coating on a polymer substrate. The additive principle is obtained using the high-pressure cold spraying (CS) method whose literature does not include an achievement as suggested in this paper, that is, to obtain a good conductive copper coating onto polymer with a very high deposition efficiency by tuning the effect of the stand-off distance, transverse speed of the nozzle, and temperature of the carrier gas on the deposition efficiency (DE) in order to overcome delamination and erosion, and thus to improve the DE. A good coating formation up to 400 µm can be obtained, which implies that a standoff distance higher than 100 mm is needed, since both a high gas temperature (400–500 °C) and high gas pressure (30 bars) are required. A nozzle scanning velocity in the range of 200–300 mm/s gives the highest DE. The results reveal that the Cu coating on PEEK reaches a DE up to 91%, leading to an electrical conductivity up to 60% IACS (International Annealed Copper Standard). Thus, parametric analysis, along with the deposition optimization, promises to be feasible for the future in terms of DE improvement along with a good electrical conductivity in CS. Full article

Cylindrical packed beds of spheres are found in many industrial and practical applications where heat and mass transfer and fluid flow occur. A proper understanding of the porous structure is imperative for the analysis and design of the performance of packed beds. The porosity of the packed bed and in particular the radial variation in porosity is of interest. When the positions and sizes of the spheres in the packed bed are known, the areas of the intersections between the spheres and selected cylindrical planes can be used to obtain the radial variation in porosity. The aim of the study is to evaluate the performance of approximate expressions that had been derived to calculate the intersection areas. Firstly, the ability of the approximate expressions to calculate the intersection area is evaluated by considering several typical sphere–cylindrical plane configurations. Secondly, the application of the approximate expressions to obtain the radial variation in porosity for a selection of cylindrical packed beds is evaluated. It is concluded that the approximate expressions should only be applied to packed beds with aspect ratios larger than 6 and for radial positions larger than 1.5 sphere diameters from the centre line of the cylindrical packed bed. Full article

To improve the powder properties of active pharmaceutical ingredients (APIs), we coated APIs with silica nanoparticles using a dry process that allowed for direct compression into tablets. The dry coating performed with different apparatuses (a batch-type high-speed shear mixer (Mechanomill) and a continuous conical screen mill (Comil)) and properties of the resulting dry-coated APIs were compared. Ethenzamide (ETZ), which has low powder flowability, was selected as the host particle to be improved and the colloidal silicas Aerosil 200 and R972 were used as the guest particles. Both coating processes and types of silica nanoparticles improved the powder flowability (angle of repose) of ETZ under unstressed conditions. Inverse gas chromatography demonstrated that dry coating with silica nanoparticles reduced the surface free energy and improved the homogeneity of the surface energy distribution of ETZ particles. Under the stress conditions of a shear cell test, the Mechnomill-based treatment improved the powder flowability of ETZ from that of untreated ETZ; however, the Comil-based treatment did not improve the flowability. The mechanical shear force exerted by Comil was apparently insufficient for interactions between host and guest particles. However, the properties of tableted ETZ were enhanced even when the silica nanoparticles were coated using Comil. Full article

Powder coatings are a green alternative to conventional solvent-borne liquid coatings, but they have the intrinsic drawback of color-matching and adjustment in production with the conventional extrusion process. In this study, an industrially applicable approach to formulate color powder coatings utilizing ultrafine powders, i.e., a powdery blending and pressing method, was invented. This novel method was validated by comparing samples prepared by the Method 1 conventional extrusion method with an extra ultramarine pigment at 3%; Method 2 powdery blending and pressing of the original coatings and the same coating with 6% ultramarine pigment utilizing regular (coarse) powder coatings; and Method 3 utilizing ultrafine powder coatings for the two coatings with the same formulations as Method 2. The coating powders were prepared to have similar particle sizes and particle size distributions, with three commonly used coating binders, namely polyester-epoxy hybrid, polyester/TGIC (triglycidyl isocyanurate), and polyurethane (PU). The powders prepared by Methods 1 and 3 had similar flow abilities in terms of angle of repose (AOR) and avalanche angle (AVA). The performance of the new coatings by Method 3 was close to or better than the ones prepared by Method 1 in terms of the specular gloss, DOI (distinctness-of-image), reflection haze and color values, being superior to Method 2. The coatings via ultrafine powders also exhibited a comparable ultramarine particle distribution in the coating cross-sections as the conventional ones, whereas the ones via regular powders had an inferior pigment dispersion. The new method can greatly enhance the production efficiency and reduce the cost of powder coatings with compound colors, especially for small batch manufacturing. Full article

Additive manufacturing (AM) as a disruptive technique has offered great potential to design and fabricate many metallic components for aerospace, medical, nuclear, and energy applications where parts have complex geometry. However, a limited number of materials suitable for the AM process is one of the shortcomings of this technique, in particular laser AM of copper (Cu) is challenging due to its high thermal conductivity and optical reflectivity, which requires higher heat input to melt powders. Fabrication of composites using AM is also very challenging and not easily achievable using the current powder bed technologies. Here, the feasibility to fabricate pure copper and copper-carbon nanotube (Cu-CNT) composites was investigated using laser powder bed fusion additive manufacturing (LPBF-AM), and 10 × 10 × 10 mm³ cubes of Cu and Cu-CNTs were made by applying a Design of Experiment (DoE) varying three parameters: laser power, laser speed, and hatch spacing at three levels. For both Cu and Cu-CNT samples, relative density above 90% and 80% were achieved, respectively. Density measurement was carried out three times for each sample, and the error was found to be less than 0.1%. Roughness measurement was performed on a 5 mm length of the sample to obtain statistically significant results. As-built Cu showed average surface roughness (R_a) below 20 µm; however, the surface of AM Cu-CNT samples showed roughness values as large as 1 mm. Due to its porous structure, the as-built Cu showed thermal conductivity of ~108 W/m·K and electrical conductivity of ~20% IACS (International Annealed Copper Standard) at room temperature, ~70% and ~80% lower than those of conventionally fabricated bulk Cu. Thermal conductivity and electrical conductivity were ~85 W/m·K and ~10% IACS for as-built Cu-CNT composites at room temperature. As-built Cu-CNTs showed higher thermal conductivity as compared to as-built Cu at a temperature range from 373 K to 873 K. Because of their large surface area, light weight, and large energy absorbing behavior, porous Cu and Cu-CNT materials can be used in electrodes, catalysts and their carriers, capacitors, heat exchangers, and heat and impact absorption. Full article

The air quality in a hospital’s underground car park is a concern because diesel fumes from cars impact upon vulnerable people attending medical consultations. This research aims to quantify the potential health risk associated with a particular hospital car park. Particulate matter was evaluated in the area with direct reading devices for particle numbers and mass concentrations (CPC 3007, EEPS 3090, Trolex Air XD, Nanozen, and Grimm 1109). Elemental and total carbon concentrations were measured following the NIOSH 5040 method, while volatile organic compounds (VOCs), and polycyclic aromatic hydrocarbons (PAHs) were measured through laboratory analysis and Scanning Electron Microscopy and Energy Dispersive using X-Ray Analysis SEM-EDX microscopy. The nanoparticle levels reached over 80,000 nanoparticles/cm³ (double the German Institut für Arbeitsschutz (IFA) benchmark levels). Diesel particulate matter levels measured as elemental carbon were around 35% of the occupational limit, and from the 49 VOCs analyzed only 13 were detected in quantities below the 0.1% of the occupational limit, while levels of the 13 PAHs analyzed, were below the laboratory limit of quantification. The study concludes that particulate matter in the underground car park can easily exceed nanoparticles benchmark levels and could be harmful, mainly to vulnerable people. It is therefore recommended that they use the outdoor car park or minimize their time in the underground one. Full article