GOALI: Aerosol processing of metal powders from multiphase precursors

1336581 PI：埃尔曼喷雾热解工艺可用于制造通过传统沉淀或气相沉积工艺无法获得的独特材料。另外的优点包括可扩展性和无溶剂的最终产品粉末。抗氧化材料如银和钯的气溶胶生产已经得到证实，但在工业规模上扩展到较低成本的贱金属一直是具有挑战性的。 该项目的目标是开发一种混合相喷雾热解路线，用于生产多组分贱金属粉末，具有更好的抗氧化保护，用于可印刷电子应用，包括混合集成电路和太阳能电池的金属化。喷雾热解将用于实现微观结构的动力学控制，从而能够形成无法通过其他手段制成的颗粒。测试床将是含有铜和铜/锡合金的颗粒，但处理方法将广泛适用于其他材料系统。一个由杜邦和马里兰州大学的学生、教师和工业研究人员组成的团队将进行实验和模拟研究，以克服与混合相粉末加工相关的技术障碍。 该团队利用了马里兰州大学在化学工程、材料表征和气溶胶技术方面的专业知识，以及杜邦公司在材料化学、粉末加工和实验统计设计方面的专业知识。这项工作的结果将使低成本的贱金属加入到导电浆料中，从而降低太阳能电池、电子产品和医疗设备的整体成本。使用基于气溶胶的金属粉末生产路线将比传统的基于沉淀的工艺实现额外的环境和成本效益。该项目的附加值包括：（1）融合工业和学术观点（2）工业和大学研究人员与学生之间的互动，这将允许从实验室创新到应用测试的所有阶段的参与，以及（3）将真实的世界元素融入大学预科和本科生的活动和研究经验。

1336581PI: EhrmanSpray pyrolysis processes can be used to make unique materials not accessible via traditional precipitation or vapor deposition processes. Additional advantages include scalability and solvent free final product powders. Aerosol production of oxidation resistant materials such as silver and palladium has been demonstrated, but extension to lower cost base metals on an industrial scale has been challenging. The objective of this project is to develop a mixed-phase spray pyrolysis route for producing multicomponent base metal powders with increased protection against oxidation, for printable electronics applications including hybrid integrated circuitry and metallization of solar cells. Spray pyrolysis will be used to achieve kinetic control of microstructure, enabling formation of particles that cannot be made by other means. The test bed will be particles that contain both copper and copper/tin alloy, but the processing approach will be broadly applicable to other material systems. A team consisting of student, faculty and industrial researchers from DuPont and the University of Maryland will conduct experimental and simulation based studies to overcome technical hurdles associated with mixed phase powder processing. This team draws upon University of Maryland expertise in chemical engineering, materials characterization and aerosol technology and DuPont expertise in materials chemistry, powder processing, and statistical design of experiments.Results of this work will enable incorporation of low cost base metals into conductive pastes, leading to overall reductions in cost for solar cells, electronics and medical devices. Use of aerosol based production routes for metal powders will realize additional environmental and cost benefits over conventional precipitation-based processes. Elements of the value added by this project include: (1) fusion of industrial and academic perspectives (2) interactions between industry and university researchers and students that will allow participation at all stages from laboratory innovation to applications testing and (3) interjection of real world elements into activities and research experiences for pre-college and undergraduate students.