GOALI: Metal alloy powders via co-solvent assisted spray pyrolysis

项目概述：本项目的目的是开发一种喷雾热解工艺，以廉价的金属盐前体为原料生产金属合金微粒。由杜邦和马里兰大学的学生、教师和工业研究人员组成的团队将进行基于实验和模拟的研究，以全面了解工艺条件和产品特性之间的关系。知识优势：喷雾热解工艺在粉末生产方面比固相工艺有许多优势，但在工业规模上，对金属的扩展仅限于少数抗氧化系统，如银和钯。为生产金属颗粒而添加高浓度还原性气体的要求在贱金属生产中推广有限。在我们的方法中，共溶剂在反应器中分解产生少量的氢，低于空气中的可燃性限制，将金属盐晶体还原为金属粉末。这一过程受动力学和热力学约束。分解过程的化学动力学模型将用于预测氢的演化，而热化学模型将用于确定平衡相关系（作为氧浓度和温度的函数），以及基于质量和能量平衡的过程模型，以及基于统计的质量控制概念来指导过程设计。通过这个项目，该团队将从实验规模的单组分概念验证阶段到多组分合金粉末形成阶段，包括工艺规模扩大和应用测试。更广泛的影响：目标应用是用于微电路材料生产的厚膜导电浆料，例如在混合集成电路中，用于收缩组件的嵌入式无源和多层陶瓷电容器的金属化。包含微电路材料的终端产品无处不在，从手机到太阳能电池再到汽车。更高质量的材料将改善通信和安全，提高能源效率，以及其他影响生活质量的改进。气雾剂为基础的生产路线，这是快速的，往往是单步，并生产溶剂和配体无产品粉末，也提供了一个普遍的机会，促进生产的可持续性。除了电子材料之外，金属粉末对于牙科和医疗植入物以及医疗设备（如糖尿病患者的血糖监测仪）也很感兴趣，因此这项研究的结果也可能影响这些行业。拟议的产学研合作所增加的价值包括：(1)反应工程、气溶胶技术和材料科学的基本原理与工业过程开发和规模化活动的融合；(2)工业和大学研究人员和学生之间的互动，将允许参与从实验室创新到应用测试和扩展研究的各个阶段，以现实世界的视角为教学和推广活动提供信息。

CBET-0755703, EhrmanProject Summary: The objective of this project is to develop a spray pyrolysis process for the production of metal alloy microparticles from inexpensive metal salt precursors.A team consisting of student, faculty and industrial researchers from DuPont and theUniversity of Maryland will conduct experimental and simulation based studies in order to develop a comprehensive understanding of relationship between process conditions and product characteristics.Intellectual Merit: Spray pyrolysis processes offer many advantages over solution phase routes for powder production, but extension to metals on an industrial scale has been restricted to only a few oxidation resistant systems such as silver and palladium. The requirement of addition of high concentrations of reducing gas to produce metallic particles has limited extension to base metal production. In our approach, the cosolvent decomposes in the reactor to produce small amounts of hydrogen, less than the flammability limit in air, reducing metal salt crystals to metallic powders. The process is governed by both kinetic and thermodynamic constraints. Chemical kinetic modeling of the decomposition process will be used to predict hydrogen evolution while thermochemical modeling to determine equilibrium phase relationships as a function of oxygen concentration and temperature will be used, together with a mass and energy balance based process model, and statistical based quality control concepts to guide process design. With this project, the team will take the process from bench scale single component proof of concept stage to multicomponent alloy powder formation, including process scale up and applications testing.Broader Impact: The target application is thick film conductive pastes used in the production of microcircuit materials, for example in hybrid integrated circuitry, embedded passives to enable shrinkage of components and metallization of multilayer ceramic capacitors. End products containing microcircuit materials are ubiquitous, ranging from cell phones to solar cells to automobiles. Better quality materials will lead to improved communications and safety, greater energy efficiency, and other improvements affecting quality of life. Aerosol-based production routes, which are rapid and often single step, and which produce solvent and ligand free product powders, also present a general opportunity for promotion of sustainability in manufacturing. Beyond electronic materials, metal powders are of interest for dental and medical implant applications as well as medical devices such as in glucose monitors for diabetics, and thus results from this research may impact these industries as well. Elements of the value added by the proposed industry-university collaboration include: (1) fusion of fundamental principles of reaction engineering, aerosol technology and materials science with industrial process development and scale up activities, and (2) interactions between industry and university researchers and students that will allow participation at all stages from laboratory innovation to applications testing and extension of the research to inform teaching and outreach activities with a real world perspective.