Aggregate morphology evolution by sintering: Number and diameter of primary particles

The structure of fractal-like agglomerates (physically bonded) and aggregates (chemically or sinter-bonded) is important in aerosol synthesis of nanoparticles, and in monitoring combustion emissions and atmospheric particles. It also influences particle mobility, scattering and eventually performance of nanocomposites, suspensions and devices made with such particles. Here, aggregate sintering by viscous flow of amorphous materials (silica, polymers) and grain boundary diffusion of crystalline ceramics (titania, alumina) or metals (Ni, Fe, Ag, etc.) is investigated. A scaling law is found between average aggregate projected area and equivalent number of constituent primary particles during sintering: from fractal-like agglomerates to aggregates and eventually compact particles (e.g. spheres). This is essentially a relation independent of time, material properties and sintering mechanisms. It is used to estimate the equivalent primary particle diameter and number in aggregates. The evolution of aggregate morphology or structure is quantified by the effective fractal dimension (Df) and mass–mobility exponent (Dfm) and the corresponding prefactors. The Dfm increases monotonically during sintering converging to 3 for a compact particle. Therefore Dfm and its prefactor could be used to gage the degree or extent of sintering of agglomerates made by a known collision mechanism. This analysis is exemplified by comparison to experiments of silver nanoparticle aggregates sintered at different temperatures in an electric tube furnace.

► Fractal-like aggregates during viscous flow and grain boundary diffusion sintering.
► Scaling law between aggregate projected area and equivalent primary particle number.
► Average primary particle size estimation from aggregate mass and mobility diameter.
► Primary particle size of current method consistent with counting TEM images.
► Mass–mobility exponent Dfm can be used to characterize degree of sintering.