SAHIL TANEJA CH-9262

NANOMATERIAL Bottom-up
(Assemble from nano building blocks) POWDER/AEROSOL COMPACTION CHEMICAL SYNTHESIS

Top-down
(Sculpt from bulk) MECHANICAL ATTRITION

The attrition, or milling, of materials has been a major component of the ceramic processing and powder metallurgy industries for many years. The objectives of milling include particle size reduction (comminution or grinding); shape changing (flaking); agglomeration; solidstate blending (incomplete alloying); modifying, changing, or altering properties of a material (density, flowability, or workhardening); and mixing or blending of two or more materials or mixed phases. However, the primary objective of milling is often purely particle size reduction. This mechanical process provides a way of mixing and combining solids from the scale of a powder particle down to the nano scale, while remaining in the solid state.

Model of impact event at a time of maximum impacting force, showing the formation of a microcompact.

The fundamental principle of size reduction in mechanical attrition devices lies in the energy imparted to the sample during impacts between the milling media. This model represents the moment of collision, during which particles are trapped between two colliding balls within a space occupied by a dense cloud, dispersion, or mass of powder particles.

Process of trapping an incremental volume of powder between two balls in a randomly agitated charge of balls and powder.

Figure shows the process of trapping an incremental volume between two balls. Compaction begins with a powder mass that is characterized by large spaces between particles compared with the particle size. The first stage of compaction starts with the rearrangement and restacking of particles. Particles slide past one another with a minimum of deformation and fracture, producing some fine, irregularly shaped particles. The second stage of compaction involves elastic and plastic deformation of particles. The third stage of compaction, involving particle fracture, results in further deformation and/or fragmentation of the particles.

As fragments decrease in size, the tendency to aggregate increases, and fracture resistance increases. Particle fineness approaches a limit as milling continues and maximum energy is expended.

The major factors contributing to grind limit are: Increasing resistance to fracture. Increasing cohesion between particles, with decreasing particle size causing agglomeration. Excessive clearance between impacting surfaces. Coating of the grinding medium by fine particles that cushion the microbed of particles from impact. Surface roughness of the grinding medium. Bridging of large particles to protect smaller particles in the microbed.

ATTRITION DEVICES
Attrition Mill- Also known as the attritor or stirred ball mill. The balls are set in motion by rotation of the central shaft on which secondary arms are fixed. The cylinder itself is fixed.

Horizontal Mill. The cylinder rotates around its horizontal axis. The combined effects of the centrifugal force induced by this rotation and gravity cause the balls to rise and fall onto the powder particles.

1D Vibratory Mill. Also known

as a shaker mill. The vessel is set in vertical oscillatory motion. Under this action, the 1-kg ball rises then falls back onto the powder particles.
Planetary Mill. The containers are fixed on a table which rotates until the centrifugal acceleration reaches 30 to 50 times the acceleration due to gravity. The containers themselves also rotate in modern mills, this rotation being either coupled or uncoupled with respect to the rotation of the table.

3D Vibratory Mill. Also known as a three-axis shaker. These operate according to the same principle as the 1D vibratory mill, but this time in a more complex way due to the 3 vibrational degrees of freedom. The balls collide with the side walls of the container (friction and impacts), but also with its floor and ceiling.

CONTAMINATION
The problem of milling atmosphere is also serious and has been found to be a major cause of contamination. It has been observed that if the container is not properly sealed, the atmosphere surrounding the container, usually air, leaks into the container and contaminates the powder. This is particularly problematic for oxidation-sensitive materials, such as pure metals.