Packings of micron-sized spherical particles – Insights from bulk density determination, X-ray microtomography and discrete element simulations

Evolution characteristics of micromechanics provides insights into the microstructure of pharmaceutical tablets fabricated by bimodal mixtures

This research focuses on the evolution of mechanical behavior of bimodal mixtures undergoing compaction and diametrical compression. The clusters were built and discrete element method (DEM) was used to investigate the densification process and micromechanics of bimodal mixtures. Additionally, a more comprehensive investigate of the respective breakage of the bimodal mixtures has been carried out. On this basis, qualitative and quantitative analysis of the compressive force, force chain, contact bonds and density field evolution characteristics of the clusters are investigated during the compression process. The entire loading process of the clusters is divided into three stages: rearrangement, breakage and elastic-plastic deformation. Additionally, there are differences in the evolution of micromechanics behavior of different particles in the bimodal mixture, with pregelatinized starch breakage and deformation occurring before microcrystalline cellulose. With the tablet deformation, the fragmentation process of the tablet started at the point of contact and extended toward the center, and the curvature of the force chain increased. This approach may potentially hold a valuable new information relevant to important transformation forms batch manufacturing to advanced manufacturing for the oral solid dosage form.

Ultraslow Settling Kinetics of Frictional Cohesive Powders

Using discrete element method simulations, we show that the settling of frictional cohesive grains under ramped-pressure compression exhibits strong history dependence and slow dynamics that are not present for grains that lack either cohesion or friction. Systems prepared by beginning with a dilute state and then ramping the pressure to a small positive value P_{final} over a time τ_{ramp} settle at packing fractions given by an inverse-logarithmic rate law, ϕ_{settled}(τ_{ramp})=ϕ_{settled}(∞)+A/[1+Bln(1+τ_{ramp}/τ_{slow})]. This law is analogous to the one obtained from classical tapping experiments on noncohesive grains, but crucially different in that τ_{slow} is set by the slow dynamics of structural void stabilization rather than the faster dynamics of bulk densification. We formulate a kinetic free-void-volume theory that predicts this ϕ_{settled}(τ_{ramp}), with ϕ_{settled}(∞)=ϕ_{ALP} and A=ϕ_{settled}(0)-ϕ_{ALP}, where ϕ_{ALP}≡.135 is the "adhesive loose packing" fraction found by Liu et al. [Equation of state for random sphere packings with arbitrary adhesion and friction, Soft Matter 13, 421 (2017)SMOABF1744-683X10.1039/C6SM02216B].

Dry powder coating in additive manufacturing

Dry powder coating is used in many industries to tailor the bulk solid characteristics of cohesive powders. Within this paper, the state of the art of dry coating of feedstock materials for powder based additive manufacturing (AM) processes will be reviewed. The focus is on feedstock materials for powder bed fusion AM processes, such as powder bed fusion of polymers with a laser beam and powder bed fusion of metals with lasers or an electron beam. Powders of several microns to several ten microns in size are used and the feedstock’s bulk solid properties, especially the flowability and packing density are of immanent importance in different process steps in particular for powder dosing and spreading of powder layers onto the building area. All these properties can be tuned by dry particle coating. Moreover, possibilities to improve AM processability and to manipulate the resulting microstructure (c.f. grain refinement, dispersion strengthening) by adhering nanoparticles on the powders will be discussed. The effect of dry coating on the obtained powder properties along the whole AM process chain and the resulting part properties is assessed. Moreover, appropriate characterization methods for bulk solid properties of dry-coated AM powders are critically discussed.

Finding the grain size distribution that produces the densest arrangement in frictional sphere packings: Revisiting and rediscovering the century-old Fuller and Thompson distribution

By means of discrete-element methods, we investigate the joint effects of the grain size distribution (GSD) and contact friction on the structure of three-dimensional samples composed of spherical grains. Specifically, we compress these systems isotropically until jamming and then analyze their structure in terms of density, connectivity, coefficients of uniformity and curvature, and parameters of grading entropy. Our study focuses on power-law GSDs and particularly on the Fuller and Thompson distribution, proposed over a century ago. First, we show that, among the set of GSDs investigated, this particular distribution produces the densest and best-connected systems, falsifying a conjecture recently posed in the literature. Second, we find that the jamming packing fraction can be accurately predicted as a function of simple descriptors of the GSD, but among these descriptors the granular entropy concept proves to be the most useful. This allows for an alternative interpretation of both jamming and grading entropy concepts. Finally, we compare the Fuller and Thompson distribution with two well-known GSDs: that of the Apollonian sphere packing and that towards which granular systems evolve after intensive grain fracturing. Surprisingly, we find that these three GSDs are practically coincident in the limit of large size spans, despite having been introduced or discovered in different scientific contexts (i.e., engineering, mathematics, and earth sciences, respectively).

Abrasion-Induced Acceleration of Melt Crystallisation of Wet Comminuted Polybutylene Terephthalate (PBT)

Within this contribution, the effect of grinding media wear on the melt crystallisation of polybutylene terephthalate (PBT) is addressed. PBT was wet ground in a stirred media mill in ethanol using different grinding media beads (silica, chrome steel, cerium-stabilised and yttrium-stabilised zirconia) at comparable stress energies with the intention to use the obtained particles as feed materials for the production of feedstocks for laser powder bed fusion additive manufacturing (PBF-AM). In PBF‑AM, the feedstock’s optical, rheological and especially thermal properties—including melt crystallisation kinetics—strongly influence the processability and properties of the manufactured parts. The influence of process parameters and used grinding media during wet comminution on the optical properties, crystal structure, molar mass distribution, inorganic content (wear) and thermal properties of the obtained powders is discussed. A grinding media-dependent acceleration of the melt crystallisation could be attributed to wear particles serving as nuclei for heterogeneous crystallisation. Yttrium-stabilised zirconia grinding beads proved to be the most suitable for the production of polymer powders for the PBF process in terms of (fast) comminution kinetics, unchanged optical properties and the least accelerated crystallisation kinetics.

An expression for the angle of repose of dry cohesive granular materials on Earth and in planetary environments

The angle between the sloping side of a heap of particles and the horizontal, called angle of repose, is often used to characterize the flowability of granular materials on Earth and planetary environments, such as sand, dust aerosols, and powders. In planetary research, this angle provides an excellent proxy for particle size. The smaller the particle is, the larger the effect of attractive forces between atoms and molecules on the surface of the particles relative to particle weight, the less flowable the material, and the steeper, thus, the angle of repose. We present a model that accurately predicts the angle of repose as a function of particle size, both on Earth and under extraterrestrial gravity.

The angle of repose—i.e., the angle θr between the sloping side of a heap of particles and the horizontal—provides one of the most important observables characterizing the packing and flowability of a granular material. However, this angle is determined by still poorly understood particle-scale processes, as the interactions between particles in the heap cause resistance to roll and slide under the action of gravity. A theoretical expression that predicts θr as a function of particle size and gravity would have impact in the engineering, environmental, and planetary sciences. Here we present such an expression, which we have derived from particle-based numerical simulations that account for both sliding and rolling resistance, as well as for nonbonded attractive particle–particle interactions (van der Waals). Our expression is simple and reproduces the angle of repose of experimental conical heaps as a function of particle size, as well as θr obtained from our simulations with gravity from 0.06 to 100 times that of Earth. Furthermore, we find that heaps undergo a transition from conical to irregular shape when the cohesive to gravitational force ratio exceeds a critical value, thus providing a proxy for particle-scale interactions from heap morphology.

Optimizing Hydrogen Storage in MOFs through Engineering of Crystal Morphology and Control of Crystal Size

Metal-organic frameworks (MOFs) are promising materials for hydrogen storage that fail to achieve expected theoretical values of volumetric storage density due to poor powder packing. A strategy that improves packing efficiency and volumetric hydrogen gas storage density dramatically through engineered morphologies and controlled-crystal size distributions is presented that holds promise for maximizing storage capacity for a given MOF. The packing density improvement, demonstrated for the benchmark sorbent MOF-5, leads to a significant enhancement of volumetric hydrogen storage performance relative to commercial MOF-5. System model projections demonstrate that engineering of crystal morphology/size or use of a bimodal distribution of cubic crystal sizes in tandem with system optimization can surpass the 25 g/L volumetric capacity of a typical 700 bar compressed storage system and exceed the DOE targets 2020 volumetric capacity (30 g/L). Finally, a critical link between improved powder packing density and reduced damage upon compaction is revealed leading to sorbents with both high surface area and high density.