Cold gas dynamic spray (CS) is a unique technique to deposit material using high strain rate solid state deformation. A major challenge for this technique is its dependence on the powder properties and lack of standards to assess them between lots and manufacturers. The motivation of this research was to understand the variability in powder atomization techniques for stainless steel powders and their subsequent properties for their corresponding impact on CS. A drastic difference (~30%) was observed in deposition efficiencies (DE) of unaltered, spherical, and similar sized stainless steel (316) powders produced using centrifugal (C.A) and traditional gas atomization (G.A) techniques. The study highlights more on differences on precursor level. Using recent advancements in large scale statistical measurements like laser diffraction shape analysis, µCT scanning, traditional methods like EBSD, nano-indentation, an attempt is made to understand the powder property. Insights on powder size and shape are documented. Significant differences were observed between C.A and G.A powders in terms of grain size, fraction of higher angle grain boundaries (HAGB) and nano hardness. The outcomes of this study would be helpful to understand the commercialization of the cold-spray process for bulk manufacturing of powder precursors

The objective of this study aimed to develop biodegradable calcium alginate microspheres carrying doxorubicin (Dox) at the micrometer-scale for sustained-release and the capacity of pH regulatory for transarterial chemoembolization. Ultrasonic atomization and CaCl2 cross-linking technologies were used to prepare the microspheres. A 4 by 5 experiment was first designed to identify imperative parameters. The concentration of CaCl2 and the flow rate of the pump were found to be critical to generate microspheres with a constant volume median diameter (~ 39 m) across 5 groups with different alginate:NaHCO3 ratios using each corresponding flow rate. In each group, the encapsulation efficiency was positively correlated to the Dox-loaded efficiency. Fourier-transform infrared spectroscopy showed that NaHCO3 and Dox were step-by-step incorporated into the calcium alginate microspheres successfully. Microspheres containing alginate:NaHCO3 = 1 exhibited rough and porous surfaces, high Young’s modulus and hardness. In each group with the same alginate:NaHCO3 ratio, the swelling rates of microspheres were higher in PBS containing 10% FBS compared to those in PBS alone. Microspheres with relative high NaHCO3 concentrations in PBS containing 10% FBS maintained better physiological pH and higher accumulated Dox release ratios. In two distinct hepatocellular carcinoma-derived cell lines, treatments with microspheres carrying Dox demonstrated that the cell viabilities decreased in groups with relative high NaHCO3 ratios in time- and dose-dependent manners. Our results suggested that biodegradable alginate microspheres containing relative high NaHCO3 concentrations improved the cytotoxicity effects in vitro.

Microencapsulation by atomization can be used to minimize the loss of bioactive compounds, improving the characteristics and applicability of the powdered product. This study evaluates the effect of different encapsulating agents (maltodextrin, gum arabic, and chitosan) and three spray nozzle diameters (1.0, 1.2, and 1.5 mm) on the atomization of guavira (Campomanesia adamantium) pulp with added 6% bocaiuva (Acrocomia aculeata) dehydrated pulp in the green maturation stage. The experiment followed a simplex-centroid mixed design, with carrier agent concentrations and spray nozzle diameters as independent variables and powder yield, solubility, hygroscopicity, and vitamin C content as dependent variables. The results show that gum arabica increased powder yield and vitamin C retention. The addition of maltodextrin resulted in powders with increased solubility and low hygroscopicity. Furthermore, the optimization tool indicated that the best process conditions were achieved with the addition of gum arabic (10.8%) and chitosan (7.2%), resulting in powders with 29.48% yield, 82.96% solubility, 15.90% hygroscopicity and 741.11 mg/100g vitamin C. Furthermore, the 1.0 mm diameter spray nozzle was considered the most suitable for obtaining guavira pulp microparticles with higher ascorbic acid content.

Pneumatic nebulizers (as variations based on the Collison nebulizer) have been widely used for producing fine aerosol droplets from a liquid material. The basic working principle of those nebulizers has been qualitatively described as utilization of the negative pressure associated with an expanding gas jet to syphon liquid into the jet stream, then to blow and shear into liquid sheets, filaments, and eventually droplets. Detailed quantitative analysis based on fluid mechanics theory is desirable, to gain in-depth understanding of the liquid aspiration mechanism among other aspects of the Collison nebulizer behaviour. The purpose of present work is to investigate the nature of negative pressure distribution associated with compressible gas jet flow in the Collison nebulizer by a computational fluid dynamics (CFD) analysis, using an OpenFOAM® compressible flow solver. The value of the negative pressure associated with a gas jet flow is examined by varying geometric parameters of the jet expansion channel adjacent to the outlet of jet orifice. Such an analysis can provide valuable insights into fundamental mechanisms for liquid aspiration, helpful for designing improved pneumatic atomizer in the Aerosol Jet® direct-write system for micro-feature, high-aspect-ratio material deposition

Innovations in drug delivery systems are crucial for enhancing therapeutic efficiency. Our research presents a novel approach based on Electro-fluid dynamic atomization (EFDA) to fabricate core-shell monophasic particles (CSMp) from sodium alginate blends of varying molecular weights. This study explores the morphological characteristics of these particles in relation to material properties and process conditions, highlighting their potential in drug delivery applications. A key aspect of our work is the development of a mathematical model that simulates the release kinetics of small molecules, specifically sodium diclofenac. By assessing the diffusion properties of different molecules and gel formulations through transport and rheological models, we have created a predictive tool for evaluating the efficiency of these particles in drug delivery. Our findings underscore two critical independent parameters for optimizing drug release: the external shell thickness and the diffusivity ratios within the dual layers. This allows for precise control over the timing and intensity of the release profile. The study advances our understanding of EFDA in the fabrication of CSMp and offers promising avenues for enhancing drug delivery systems by tailoring release profiles through particle characteristic manipulation.

Spray technology is widely used in various industries, including medicine, food production, mechanical engineering, and nanopowder manufacturing. Achieving high dispersion and a narrow particle size distribution is crucial for many applications. Ultrasonic spraying is commonly used to achieve this. On other hand, hydraulic nozzles provide high atomization performance. Combining these two technologies promises to offer significant benefits, but the complex processes that occur simultaneously in such a device require careful study. This work proposes a fundamental design for an acoustic-hydraulic nozzle and investigates the physical processes when a liquid is sprayed using this nozzle, both theoretically and experimentally. The study identifies the critical modes of spraying and confirms that the simultaneous use of ultrasound and hydraulic pressure can produce a fine spray (droplet size less than 50 μm) with high productivity (5-10 ml/s). This approach has significant potential for modern industries and technologies.

Spraying various liquids (primarily aqueous solutions of various substances) is widely used in various technological processes. For most of them, high dispersibility and narrow droplet size distribution are essential. This facilitates ultrasonic spray technique. However, the higher the dispersity of droplets produced by ultrasonic spray, the lower the spray productivity. To solve this problem, we proposed a method of multistage spraying, consisting in generation of a large number of particles of large initial size (to ensure high productivity) and their subsequent destruction by propagation in a periodic ultrasonic field (to ensure small droplet sizes at high productivity). To experimentally determine the capabilities of this technique, a tubular emitter in the shape of a cylinder of stepped-variable cross-section was designed. Configuration of the ultrasonic field inside the emitter (22.2 kHz; 182 dB) implements three-stage spraying (the number of sputtering stages corresponds to the number of anti-nodes along the emitter axis). The effectiveness of proposed and developed technique suitable for generation of droplets sized less than 40 µm with performance exceeding the known ultrasonic spray techniques at least 10 times has been confirmed in the course of conducted research.