Fabrication of composite microspheres doped with nano-aluminum powder using melt spray technology

Liu Yilin; Zhang Lanqi; Yin Yulong; Li Nan; Chu Xiangnan; Ma Qi; Liu Jing; Yang Wenbo; Lv Yingdi; Tao Shengyang

doi:10.1016/j.cjche.2025.09.014

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Fabrication of composite microspheres doped with nano-aluminum powder using melt spray technology

Updated：2026-05-14

- Fabrication of composite microspheres doped with nano-aluminum powder using melt spray technology
- Chinese Journal of Chemical Engineering Vol. 90, Issue 2, Pages: 283-292(2026)
- Affiliations：
  
  School of Chemistry, State Key Laboratory of Fine Chemicals, Frontier Science Center for Smart Materials, Dalian Key Laboratory of Intelligent Chemistry, Dalian University of Technology, Dalian 116024, China
  China Nuclear Power Operations Co., Ltd., Shenzhen 518000, China
  Suzhou Nuclear Power Research Institute Co., Ltd., Suzhou 215004, China
  Yangjiang Nuclear Power Co., Ltd., Yangjiang 529941, China
  School of Chemistry and Chemical Engineering, Northwestern Polytechnical University, Xi'an 710129, China
  Xi'an Modern Chemistry Research Institute, Xi'an 710065, China
- Author bio：
  
  Corresponding authors. E-mail addresses: wbyang@dlut.edu.cn (W. Yang)
  Corresponding authors. E-mail addresses: imlv1984@126.com (Y. Lv)
  Corresponding authors. E-mail addresses: taosy@dlut.edu.cn (S. Tao).
- Funds：
- DOI：10.1016/j.cjche.2025.09.014
  CLC：
- Received：26 July 2025，
  
  Revised：2025-09-21，
  
  Accepted：22 September 2025，
  
  Online First：17 October 2025，
  
  Published：2026-02
- Accepted：
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Liu Yilin, Zhang Lanqi, Yin Yulong, et al. Fabrication of composite microspheres doped with nano-aluminum powder using melt spray technology[J]. Chinese Journal of Chemical Engineering, 2026, 90(2): 283-292.
DOI：

Liu Yilin, Zhang Lanqi, Yin Yulong, et al. Fabrication of composite microspheres doped with nano-aluminum powder using melt spray technology[J]. Chinese Journal of Chemical Engineering, 2026, 90(2): 283-292. DOI： 10.1016/j.cjche.2025.09.014.

摘要

Abstract

Melt spray technology serves as an effective method for fabricating spherical micro-nano composite materials

with established applications in catalysts and pharmaceuticals. This study extends its application to energetic composite microspheres

investigating the microsphere formation process using nano-aluminum powder (nano-Al) combined with the inert surrogate sucrose octaacetate (SOA). This study systematically investigates the effects of process parameters

formulation composition

and storage conditions on the particle size

morphology

and stability of SOA/Al composite microspheres. Higher atomizing gas pressure and temperature significantly reduced median particle diameter (

)

yielding a

of 35.09 μm at 150℃ and 200 kPa. The addition of polyethylene glycol: polyvinylpyrrolidone (1:1) enhanced microsphere circularity from 0.67 to 0.85. This system produced 78 g composite microspheres within 20 min

demonstrating efficient lab-scale production. X-ray diffraction and differential scanning calorimetry results indicated that rapid cooling led to amorphous structures

which were stabilized during storage at 4℃. The scalable melt spray fabrication strategy developed here for nanoparticle-doped composite microspheres provides a basis for future studies involving diverse functional composites.

关键词

Keywords

references

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