Powders, Volume 2, Issue 2 (June 2023) – 17 articles

The paper demonstrates the potential of wet ball milling of metals for the synthesis of various carbides and carbohydrides. The work reports on multicomponent carbides formed in Ti-(Cu/Fe/Si)-C, W-Fe-C, and Nb-(Cu/Fe/Si/Al)-C systems, as well as metastable or high-temperature intermetallics formed in Ti-Si, Nb-Si, Nb-Al, and Nb-Cu-Fe systems, which are stabilized with interstitial carbon. The formation of phase composition of powders fabricated under mechanochemical synthesis and subsequent thermal treatment has been studied. The as-fabricated powders have been used to produce bulk compacts and to apply wear-resistant coatings on steel (iron). Full article

The FeAl intermetallic compound is of great interest for industry due to its low density, low cost and high mechanical and corrosion resistance, so it can replace stainless steels and nickel-based alloys for some applications. In previous publications, the concept (principle) test for a novel FeAl powder manufacturing process has been shown. It consists mainly of the following stages: (a) metallic strip manufacture through rapid solidification, (b) water vapor exposure of these metallic strips for their disintegration and powder generation and (c) powder drying. Experimental tests were performed for 2 g of the FeAl intermetallic compound. However, this process can be extended to manufacture any other intermetallic compound containing aluminum, such as TiAl, NiAl, CoAl or any other that can be obtained from every element that can combine with aluminum, if the aluminum content is between 55 and 60 at.%. Nowadays, this process is at technology readiness level (TRL) 3. Therefore, in this paper, a process equipment up-scaling configuration for producing up to 15 kg powder is proposed. This manufacturing process is an industrial alternative to those commonly used to produce powders of this type of intermetallic compounds, such as mechanical alloying (MA). Moreover, several alternatives for employing renewable energy sources are given, making it even more environmentally sustainable. Full article

A novel method of the hot consolidation metal powders with shear deformation is proposed. The powders were encapsulated into tight containers and compacted after short-term heating in a furnace preheated to 900 °C. The method prevents powder oxidation, peripheral spalling and ensures the removal of the oxide films from the powder surfaces. Commercial titanium powders of different dispersivities and impurity concentrations were hot-compacted. The microstructure, hardness and bending strength of the compacts were investigated. The compacts from fine PTOM-1 powder, containing 0.32% of hydrogen, reveal the greatest values of the hardness and bending strength. Additional annealing results in 60% increase in the bending strength. Full article

Mechanochemistry is one of the ten great discoveries of green chemistry methods for synthesizing new substances. A drug substance from the fluoroquinolone group was exposed to high-intensity mechanical impacts using a laboratory knife mill for 21 min and constantly monitored by analyzing samples extracted every 3 min with DLS, SLS, LALLS, 2D-LS, optical and digital microscopy, FTIR, and Spirotox methods. A dispersity phenomenon was detected in an area where catastrophic dislocations formed and multiplied via laser methods. The positive correlation between the temperature of deformation and stress was demonstrated, similar to a typical stress–strain curve of a Bochvar–Oding curve and Young’s modulus: the angular coefficient of the straight section to OX was tgα = 10 min⁻¹. Z-Average, ζ-potential, and polydispersity index dependences were represented as discontinuous periodic oscillations analogous to the defect and impurity transitions near the dislocation core. Deformation r from the high-intensity mechanical impact resulted in covalent bonds showing hyper- and hypochromic effects under FTIR spectra, a bathochromic shift of the maximum, and an oscillation emission at 3240 cm⁻¹. A 2D-LS fingerprint diagram obtained via the topological convolution of the light scattering matrix made it possible to distinguish the off-loading samples from the native substance. The investigation of the dissolution kinetics in water via laser diffraction led to conclusions about the limiting diffusion stage and the acceleration of the mechanoactivation of the solid body’s dissolution under both linear and plastic deformation. The acceleration of ^obsE_a of the cell death process in the temperature range from 296 to 302 K indicated a significant (2.5-fold) decrease in the toxicity of the aqueous 9 mM (1:3) sample solution at 21 min compared to that of the native levofloxacin. Adherence to the mechanochemistry laws provides an opportunity for drug repositioning to change their brand status by identifying new physicochemical and biological properties. Full article

In the present work, we studied the interaction of polyphenylsilsesquioxane with various β-diketonate complexes of titanium by mechanochemical activation. Polyphenylsilsesquioxane, bis-(2,4-pentanedionate) titanium dichloride, bis-(1-phenyl-1,3-butanedionate) titanium dichloride, and bis-(1,3-diphenyl-1,3-propanedionate) titanium dichloride were used as starting reagents. Various chemical and physicochemical methods of analysis were used to study the synthesis products. The composition of the obtained compounds has been determined. It is shown that under conditions of mechanochemical activation, high-molecular-weight products with a Si/Ti ratio different from the specified ones are formed. In addition, under the action of mechanical stresses, the initial titanium complexes (except for acetylacetonate complex) polymerize with the formation of coordination of high-molecular-weight compounds, which are destroyed by the addition of ethyl alcohol. It has been established that with an increase in the volume of the organic ligand, titanium atoms enter the polymer siloxane chain to a lesser extent. This work is aimed at finding efficient and environmentally friendly methods for the synthesis and modification of organometallic macromolecular compounds. Full article

Changes in the morphology of betulin crystals during heating at selected temperatures corresponding to polymorphic transformations were investigated. It was shown that the prismatic crystals of starting betulin form III were converted into needles at 120 °C after water removal, followed by the III→II polymorphic transformation. During further heating up to 180 °C, the whiskers of betulin form I were grown. Experiments on betulin heating in the presence of dicarboxylic acids, adipic or suberic showed that the morphological changes can serve as a test for the formation of cocrystals. According to morphological changes, the formation of cocrystals of betulin with adipic acid under heating was identified. The interaction of adipic acid vapor with the surface of betulin crystals was suggested. In contrast, morphological changes in the mixture of betulin and suberic acid under heating provided only the evidence of polymorphic transformations of the components. The results on cocrystal formation by heating were compared with the preparation of cocrystals by the liquid-assistance grinding method. Despite the fact that polymorphic forms with a high surface area were formed when betulin was heated, dissolution studies showed that the starting betulin polymorph III exhibited the highest dissolution rate in comparison with betulin polymorphs obtained under heating. Full article

In this work, a simple, inexpensive, and eco-friendly synthesis method of Cu−Ag microflakes has been developed. Firstly, Cu nanoparticles were synthesized by the reduction of copper nitrate in ethylene glycol at 180 °C in the presence of NaOH. The as-synthesized Cu powder was then dispersed in a mixture of ethyl alcohol and a dispersant followed by the mechanochemical treatment of the dispersion in a ball mill resulting in the formation of Cu flakes of approximately 0.2 μm thick and 2.7 μm lateral size. Next, by adding AgNO₃ dissolved in H₂O into the Cu particle dispersion, the bimetallic Cu−Ag microflakes were prepared. The particles so prepared were investigated by X-ray phase analysis and electron microscopy. It was shown that the Cu−Ag bimetallic particles were also flake-like in shape and similar in size to the original Cu microflakes. The effect of synthesis conditions, including parameters of mechanochemical processing, on thickness, size, and uniformity of the bimetallic microflakes was studied. The results obtained in this study were compared with those obtained by wet chemical synthesis alone. The flake-like Cu–Ag particles are supposed to be used in the manufacture of conductive pastes, adhesives, and composites for printed electronics. Full article

Powder mixtures based on copper or iron are used as metal binder materials in the manufacturing of abrasive and cutting tools. This article discusses some aspects and possibilities of using a high-energy ball milling process to modify the structure and properties of Cu-Sn, Cu-Sn-Ti and Fe-Ti powders, their sintered materials and composites with diamond. The structures of powders and sintered materials, as well as the binder-to-diamond interfaces in metal matrix composites with diamond fillers, were studied by XRD analysis, scanning electron microscopy and X-ray spectroscopy. Tribological properties and thermal stability of materials in the temperature range of 250–800 °C were investigated. Various mechanisms of dispersion strengthening during the heating of sintered materials are described. It is shown that due to the grain boundary distribution of titanium, it is possible to obtain single-phase powders in the form of a supersaturated solid solution of CuSn20Ti5 and FeTi20, which ensure the formation of thermally hardened alloys with a microhardness of 357–408 HV and 561–622 HV, respectively, in the temperature range of 350–800 °C. The wear resistance of sintered powder alloys increases more than twice. Furthermore, the simultaneous enhancement in both the strength and ductility of metal–diamond titanium-containing composites is achieved through the nanostructural state and the formation of a thin layer (up to 2 μm) of titanium carbide at the interface between the metal matrix and diamond. The developed alloy shows great potential as a binder in diamond tools which are designed for machining abrasive materials. Full article

The grossular garnet from rodingite-type rock from the Suva Česma area in western Serbia is characterized with its weak anisotropic nature. Because its anisotropy could indicate a non-cubic lower symmetry, SEM-EDS and Rietveld powder refinement methods were used. The SEM-EDS results have shown that the garnet has a (Ca_3.00Mn_0.01)_3.01(Al_1.82Fe_0.15Ti_0.02)_1.99(Si_2.97Al_0.03)_3.00O₁₂ chemical composition (i.e., Grs₉₁Adr₀₈), which can be more specifically explained as ferric iron containing grossular. The next step further used Rietveld powder refinements of the various crystal structures in the Ia‾3d, R‾3c, R‾3, I4₁/a, Fddd, C2/c, and I‾1 space groups as well as a single mixture, which was followed by a comparative analysis of the R-values, site occupancy factors, and bond lengths and angles. The synthesis of these results showed both that the studied grossular garnet is not cubic and that it crystallized in the disordered Fddd space group with the final R_B = 5.29% and R_F = 1.75%. It was presumed that the grossular formed at temperatures between 150 and ~600 °C. Full article

In this study, hydroxyapatite with the substitution of calcium cations by iron and phosphate by silicate groups was synthesized via a mechanochemical method. The as-prepared compounds have the general formula Ca_10−xFe_x(PO₄)_6−x(SiO₄)_x(OH)_2−xO_x/2 with x = 0–1.5. The thermal stability of the as-prepared compounds was studied by ex situ annealing of powders in a furnace. It has been established that, at 800 °C for x ≤ 0.5, a partial decomposition of the substituted apatites occurs with the formation of the β–Ca₃(PO₄)₂ phase. At high “x” values, the formation of this phase starts at the lower temperature of 700 °C, followed by the formation of Fe₂O₃ at 900 °C. The introduction of iron and silicate ions into the hydroxyapatite lattice was shown to decrease its thermal stability. Full article

Practically all particle separation processes depend on more than one particulate property. In the case of the industrially important froth flotation separation, these properties concern wettability, composition, size and shape. Therefore, it is useful to analyze different particle descriptors when studying the influence of particle wettability and morphology on the separation behavior of particle systems. A common tool for classifying particle separation processes are Tromp functions. Recently, multivariate Tromp functions, computed by means of non-parametric kernel density estimation, have emerged which characterize the separation behavior with respect to multidimensional vectors of particle descriptors. In the present paper, an alternative parametric approach based on copulas is proposed in order to compute multivariate Tromp functions and, in this way, to characterize the separation behavior of particle systems. In particular, bivariate Tromp functions for the area-equivalent diameter and aspect ratio of glass particles with different morphologies and surface modification have been computed, based on image characterization by means of mineral liberation analysis (MLA). Comparing the obtained Tromp functions with one another reveals the combined influence of multiple factors, in this case particle wettability, morphology and size, on the separation behavior and introduces an innovative approach for evaluating multidimensional separation. In addition, we extend the parametric copula-based method for the computation of multivariate Tromp functions, in order to characterize separation processes, also in the case when image measurements are not available for all separated fractions. Full article

Crystalline hematite nanoparticles as adsorbents for anionic Congo red dye were prepared by a hydrothermal process using urea hydrolysis. To examine the effects of coexisting anions in a solution on the formation of hematite nanoparticles, different iron(III) salts, including iron chloride hexahydrate, iron nitrate nonahydrate, iron sulfate n-hydrate, ammonium iron sulfate dodecahydrate, and basic ferric acetate, were employed as iron-ion sources. After the hydrothermal treatment of the solution, consisting of an iron salt and urea at 423 K for 20 h, a single phase of hematite was formed from the iron-nitrate solution. The results suggested that the hydrothermal formation of hematite depended on the stability of iron complexes formed in the starting solution. The average crystallite size and median diameter of hematite nanoparticles also depended on the coexisting anions, suggesting that the appropriate selection of the coexisting anions in the starting solution can allow for control of the crystallite size and particle diameter of hematite nanoparticles. The Congo red adsorption kinetics and isotherms of the hematite nanoparticles were described by the Elovich model and Langmuir model, respectively. The adsorption thermodynamics parameters were estimated, which suggested an exothermic and spontaneous process. The results demonstrated good adsorption properties for Congo red adsorption. Full article

Flaxseed oil is rich in polyunsaturated fatty acids, and its incorporation into food formulations is limited due to its hydrophobic nature and susceptibility to oxidation. The aim of this work was to analyze the effect of wall material mixtures (modified starch Capsul^® and rice and pea protein concentrate) on the efficiency of flaxseed oil encapsulation by freeze-drying, physical characterization, and determining oxidative stability. For the preparation of powders, four emulsions with an oil–wall material ratio of 1:3 were produced and characterized. The mass ratio between rice and pea proteins was fixed at 50–50%. The mass ratio of the protein-Capsul^® mixtures was varied by 0–100%, 10–90%, 20–80%, and 30–70%. Based on the creaming index results, all emulsions showed good stability after 24 h of analysis. The powders showed low moisture content (<3.23%), bulk density (<0.2659 kg/kg), and packed bulk density (<0.4389 kg/kg). Encapsulation efficiency decreased with increasing protein content, ranging from 93.40% (protein-Capsul^® ratio of 0–100%) to 18.26% (protein-Capsul^® ratio of 30–70%). However, the best oxidative stability results (smaller increases in the peroxide index values at the end of the stability experiments) were obtained for the powders containing the highest levels of vegetable proteins (protein-Capsul^® ratio of 20–80% and 30–70%, respectively). Full article

The harsh and hostile internal environment of semi-autogenous (SAG) mills renders real-time monitoring of some critical variables practically unmeasured. Typically, feed size fractions are known to cause mill fluctuations and impede the consistent processing behaviour of ores. There is, therefore, the need for continuous monitoring of mill parameters for optimal operation. In this paper, an acoustic-based sensing method is employed to estimate, in real time, a snapshot of the different feed size fractions presented to a laboratory-scale SAG mill. Employing the MATLAB 2020b programme, the mill acoustic signal is processed using various transform techniques such as power spectral density estimate (PSDE) by Welch’s method, discrete wavelet transform (DWT), wavelet packet transform (WPT), empirical mode decomposition (EMD), and variational mode decomposition (VMD). Different fractional bandpowers are obtained from the PSDE spectrum, while the statistical root mean square values are further extracted from DWT, WPT, EMD, and VMD as feature vectors. The features are used as input features in different machine-learning classification algorithms for different mill feed size fractions predictions. The various transform techniques and feed size fraction predictions are evaluated using the various performance indicators obtained from the confusion matrix such as accuracy, precision, sensitivity and F1 score. The study showed that the acoustic signal feature extraction techniques used in conjunction with the Support Vector Machine (SVM), linear discriminant analysis (LDA), and ensemble with subclass discriminant machine learning algorithms demonstrated improved performance for predicting feed size variations. Full article

The growing increase in emissions of ultrafine particles or nanoparticles by industries and urban centers has become worrisome due to the potential adverse health effects when inhaled. Particles in this size range have greater ease of pulmonary penetration, being able to access the bloodstream and deposit in other regions of the body. Thus, the development and optimization of equipment and processes aimed at the removal of aerosols of nanoparticles have been gaining importance in this current scenario. Among the equipment commonly used, electrostatic precipitators and filters stand out as being versatile and consolidated processes in the literature. This review explores and analyzes the theoretical bases of these two processes in the collection of such small particles in addition to providing a general overview of the development of technologies and studies on these topics. Full article

In the last decade, twin-screw wet granulation became an essential technology for continuous pharmaceutical tablet production. Consequently, interest in (semi-)continuous fluidized bed drying systems as a subsequent processing unit has grown. In parallel, it has become pivotal to fully understand and control manufacturing processes in line with in the quality-by-design paradigm. Formulation-generic prediction models would enormously facilitate digitally enhanced process development and require dedicated experimental data collection and process knowledge. To obtain this knowledge, three experimental campaigns were performed in this work. Firstly, an investigation into the effect of dryer process settings on drying behavior is presented. Secondly, the effect of active pharmaceutical ingredient properties on drying was assessed by producing granules of similar particle size and porosity and evaluating their drying and breakage behavior. Finally, additional experiments with varying active pharmaceutical ingredients and drug load were conducted to increase the genericity of the data set. This knowledge can be used in mathematical process modelling. Full article

In modern cold rolling mills in the steel industry, iron oxide powder is produced as a by-product when used pickling agents are recycled. Further processing of these iron oxide powders could enable the production of iron powder for various applications in powder metallurgy. For this purpose, a new process route with an eco-friendly hydrogen reduction treatment was developed. The process is able to manufacture a variety of iron particles through minor process adaptations. It was possible to manufacture spherical iron particles with high flowability. The flowability was measured by a Revolution Powder Analyzer, and an avalanche angle of 47.7° of the iron particles was determined. In addition, the bulk density measurements of the processed iron particles collective achieved values of 3.58 g/cm³, and a spherical morphology could be observed by SEM analysis. The achieved properties of the iron particles show high potential for applications where high flowability is required, e.g., additive manufacturing, thermal spray and hot isostatic pressing. By adjusting the process conditions of the developed process, irregular iron particles could also be manufactured from the same iron oxide powder with a very high specific surface of 1640 cm²/g and a low bulk density of 1.23 g/cm³. Therefore, the property profile is suitable as a friction powder metallurgy material. In summary, the developed process in combination with the iron oxide powder from steel production offers a cost-efficient and sustainable alternative to conventional iron powders for additive manufacturing and friction applications. Full article