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

Your Location：

Home >

Browse articles >

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
- Fabrication of composite microspheres doped with nano-aluminum powder using melt spray technology
- 中国化学工程学报（英文） 2026年90卷第2期页码：283-292
- 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：
  
  the National Natural Science Foundation of China(22272017;22372025);the Excellent Youth Fund of Liaoning Province(2024JH3/10200005);the Fundamental Research Funds for the Central Universities(DUT25Z2722;DUT22LAB607)
- DOI：10.1016/j.cjche.2025.09.014
  中图分类号：
- 收稿：2025-07-26，
  
  修回：2025-09-21，
  
  录用：2025-09-22，
  
  网络首发：2025-10-17，
  
  纸质出版：2026-02
- Accepted：
Scan QR Code
Liu Yilin, Zhang Lanqi, Yin Yulong, 等. Fabrication of composite microspheres doped with nano-aluminum powder using melt spray technology[J]. 中国化学工程学报（英文）, 2026,90(2):283-292.

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.
Liu Yilin, Zhang Lanqi, Yin Yulong, 等. Fabrication of composite microspheres doped with nano-aluminum powder using melt spray technology[J]. 中国化学工程学报（英文）, 2026,90(2):283-292. DOI： 10.1016/j.cjche.2025.09.014.

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

G.N. Kokila, C. Mallikarjunaswamy, V.L. Ranganatha, A review on synthesis and applications of versatile nanomaterials, Inorg. Nano Met. Chem. 54 (10) (2024)942—971.

X.J. Zhu, C. Vo, M. Taylor, B.R. Smith, Non-spherical micro-and nanoparticles in nanomedicine, Mater. Horiz. 6(6)(2019)1094—1121.

X. Wang, H.Y. Li, C. Chen, Z.H. Liang, Understanding of endo/lysosomal escape of nanomaterials in biomedical application, Smart Mol. (2025)e20240017.

X.H. Cao, C.L. Tan, M. Sindoro, H. Zhang, Hybrid micro-/nano-structures derived from metal—organic frameworks: preparation and applications in energy storage and conversion, Chem. Soc. Rev. 46(10) (2017)2660—2677.

Y.F. Si, Z.G. Guo, Superhydrophobic nanocoatings: from materials to fabrications and to applications, Nanoscale 7 (14) (2015) 5922—5946.

C. Zhang, D.J. Wu, L.M. Shi, Y.P. Zhu, D.Y. Xiong, S.H. Xu, R. Huang, R.J. Qi, W.C. Zhang, L.W. Wang, P.K. Chu, Manganese molybdate nanoflakes on silicon microchannel plates as novel nano energetic material, R. Soc. Open Sci. 4(12) (2017)171229.

N.M. Song, L. Yang, J.M. Han, J.C. Liu, G.Y. Zhang, H.X. Gao, Catalytic study on thermal decomposition of Cu-en/(AP, CL-2 0, RDX and HMX) composite microspheres prepared by spray drying, New J. Chem. 42 (23) (2018) 19062—19069.

H.H. Zhou, R. Pujales-Paradela, P. Groppe, S. Wintzheimer, K. Mandel, Tuning the morphology of spray-dried supraparticles: effects of building block size and concentration, Part. Part. Syst. Char. 39(11)(2022)2200127.

W.Y. Wu, W.J. Liu, X.J. Fu, L. Xu, D.Q. Fan, X.D. Li, S.Q. Hu, Construction of HMX/FOX-7 composite microspheres with controlled microstructures using continuous self-assembly spray drying: to improve safety and combustion performance, Mater. Chem. Phys. 339(2025)130795.

K. Zhao, J. Zhao, C.J. Wu, S.W. Zhang, Z.W. Deng, X.X. Hu, M.L. Chen, B. Peng, Fabrication of silver-decorated sulfonated polystyrene microspheres for surface-enhanced Raman scattering and antibacterial applications, RSC Adv. 5 (85)(2015)69543—69554.

H. Yabu, Fabrication of nanostructured composite microspheres based on the self-assembly of polymers and functional nanomaterials, Part. Part. Syst. Char. 36(9) (2019)1900178.

H.X. Liu, C.B. Zhou, X.Y. Liu, Y. Xu, S.M. Geng, Y.H. Chen, C. Wei, C.B. Yu, PMMA@SCNC composite microspheres prepared from Pickering emulsion template as curcumin delivery carriers, J. Appl. Polym. Sci. 135(15)(2018)46127.

Y. Gong, Q.L. Liu, A.M. Zhu, Q.G. Zhang, One-pot synthesis of poly( N -isopropylacrylamide)/chitosan composite microspheres via microemulsion, Carbohydr. Polym. 90 (1) (2012) 690—695.

S.Y. Kashani, A. Afzalian, F. Shirinichi, M. Keshavarz Moraveji, Microfluidics for core—shell drug carrier particles—a review, RSC Adv. 11 (1) (2021) 229—249.

W.B. Zuo, N. Li, Y. Zhao, T.T. Fu, W.L. Fei, R. Yu, J.H. Yang, Synchronized release of bufadienolides in a stable Lutrol F127 based solid dispersion prepared with spray congealing, Drug Dev. Ind. Pharm. 44(11)(2018)1817—1825.

W.J. Liu, F.Z. Cai, X.D. Li, P.L. Kang, Q.C. Jiang, J.B. Guo, Spherical preparation and performance analysis of FOX-7/RDX energetic composite particles, Mater. Today Commun. 47 (2025)113180.

C. Engelmann, U. Kragl, Spray congealing as innovative technique for enzyme encapsulation, J. Chem. Technol. Biotechnol. 93(1)(2018)191—197.

S. Bertoni, B. Albertini, N. Passerini, Spray congealing: an emerging technology to prepare solid dispersions with enhanced oral bioavailability of poorly water soluble drugs, Molecules 24 (19) (2019) 3471.

H. Tang, Y.T. Wang, W.J. Zhang, L. Shen, Y.B. Duan, J. Hu, Influence of heat treatment on lithium orthosilicate pebbles, Adv. Mater. Res. 624 (2012) 208—211.

Z.P. Cheng, X.Z. Chu, W. Zhao, J.Z. Yin, B.L . Dai, H. Zhong, J.M. Xu, Y. Jiang, Controllable synthesis of Cu/Al energetic nanocomposites with excellent heat release and combustion performance, Appl. Surf. Sci. 513(2020)145704.

S.J. Wang, D. Wang, P. Chen, S. Yan, Q.J. Jiao, X.Y. Guo, Preparation and characterization of Al@TKX-50@NC composite microspheres by electrospray, Mater. Chem. Phys. 305(2023)127910.

M. Yang, D.Z. Gao, T. Wen, J. Guo, X.Q. Zhang, Q. Wang, C.P. Guo, Efficient construction of Al/F microspheres in Pickering emulsion to regulate combustion reactivity, J. Mater. Sci. 59 (7) (2024) 2828—2840.

M.H. Li, A.M. Pang, W. Li, Y.Y. Zhang, X.W. Lv, Z.Y. Ma, Combustion performances of spherical Al/AP nanoenergetic composites produced by solvent evaporation and crystallization, Combust. Sci. Technol. 194 (4) (2022) 801—814.

W.Q. Pang, X.Z. Fan, K. Wang, Y.M. Chao, H.X. Xu, Z. Qin, F.Q. Zhao, Al-based nano-sized composite energetic materials (nano-CEMs): preparation, characterization, and performance, Nanomaterials 10 (6) (2020) 1039.

J.Q. Jing, X.Y. Zhang, L. Gao, F.B. Gao, H.B. Huo, S.C. Shi, W.J. Cheng, C.H. Xu, J. Y. Wang, C.W. An, Continuous preparation of multi-scale HMX-based energetic composite microspheres by pipe-stream technology, Powder Technol. 426 (2023) 118640.

X.Y. Zhang, J.Q. Jing, J.Y. Liu, L.T. Zhang, L.X. Qi, C.W. An, Continuous pipestream self-assembly technology for preparat ion of high sphericity FOX-7/HMX energetic composite microspheres, APL Mater. 12 (5) (2024) 051111.

F.Y. Chen, C.L. Xuan, Q.Q. Lu, L. Xiao, J.Q. Yang, Y.B. Hu, G.P. Zhang, Y.L. Wang, F.Q. Zhao, G.Z. Hao, W. Jiang, A review on the high energy oxidizer ammonium dinitramide: its synthesis, thermal decomposition, hygroscopicity, and application in energetic materials, Def. Technol. 19 (2023) 163—195.

B. Liu, Y.F. Yang, J. Dong, J.P. Zhang, Design of mineral oil/stearic acid hybrid coatings for reducing hygroscopicity of ammonium nitrate, Langmuir 40(31) (2024)16653—16661.

J.H. Yu, Y. Kou, L. Xiao, Q.Q. Lu, X.R. Xu, J.Q. Yang, W. Jiang, G.Z. Hao, Efficient construction of core/double-shelled structured AP@nano-graphite@F(2603) energetic microcapsules with low sensitivity and hygroscopicity, Nanoscale 17(5)(2025)2769—2781.

W.C. Stagner, S. Gaddam, R. Parmar, A.K. Ghanta, Sucrose octaacetate, in:Profiles of Drug Substances, Excipients and Related Methodology, vol. 44, Academic Press, Amsterdam,267—291(2019).

E.L. Dreizin, Metal-based reactive nanomaterials, Prog. Energy Combust. Sci. 35(2)(2009)141—167.

G.K. Batchelor, An Introduction to Fluid Dynamics, Cambridge University Press, Cambridge(2000).

C.Y. Yu, B.H. Wang, X.Z. Wang, Spray Drying Technology, Chemical Industry Press, Beijing(2013). (in Chinese)

R.P.F.N. Dombrows ki, A photographic investigation into the disintegration of liquid sheets, Philos. Trans. R. Soc. Lond. Ser. A Math , Phys. Sci. 247(924)(1954) 101—130.

R. Thakkar, R. Thakkar, A. Pillai, E.A. Ashour, M.A. Repka, Systematic screening of pharmaceutical polymers for hot melt extrusion processing: a comprehensive review, Int. J. Pharm. 576(2020)118989.

P.G. Debenedetti, F.H. Stillinger, Supercooled liquids and the glass transition, Nature 410(6825) (2001)259—267.

C. Bhugra, M.J. Pikal, Role of thermodynamic, molecular, and kinetic factors in crystallization from the amorphous state, J. Pharm. Sci. 97 (4) (2008) 1329—1349.

I.S. Gutzow, J.W.P. Schmelzer, The Vitreous State: Thermodynamics, Structure, Rheology, and Crystallization, Springer, Berlin (2013).

J.J. Zhang, S. Qian, Y. Gao, Theory and Practice of Polymorphic Drug Development, Chemical Industry Press, Beijing (2019). (in Chinese)

浏览量

Downloads

CSCD

文章被引用时，请邮件提醒。

Submit

工具集

关联资源

Research on the electrostatic spray characteristics of ethanol/n-butanol blended fuels

Tailoring the molecular structure of cross-linked poly(ethylene oxide) membranes for enhanced CO2 permeation

CO2 capture by ternary ionic liquid non-aqueous phase change solvents

Synergistically coupling of vertically oriented Ru/Co co-doped MoS2 with interfacial engineering for efficient electrochemical hydrogen evolution

Biochar as a structure-tunable stationary phase for column chromatographic fractionation of bio-oil