Development and experimental–Numerical investigation of alumina powder spheroidization and hollow sphere formation using a novel conical RF-ICP torch.
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| Title: | Development and experimental–Numerical investigation of alumina powder spheroidization and hollow sphere formation using a novel conical RF-ICP torch. |
|---|---|
| Authors: | Ebrahimi, Ali1 (AUTHOR), Alavi, Sina1 (AUTHOR), Mostaghimi, Javad1 (AUTHOR) javad.mostaghimi@utoronto.ca |
| Source: | Ceramics International. Jul2026, Vol. 52 Issue 17, p32290-32307. 18p. |
| Subjects: | Plasma materials processing, Ceramic powders, Plasma jets, Magnetohydrodynamics |
| Abstract: | A novel conical radio-frequency inductively coupled plasma (RF–ICP) torch is developed and systematically evaluated for alumina powder spheroidization. Magnetohydrodynamic (MHD) simulations coupled with discrete particle tracking are integrated with in-flight diagnostics (DPV-2000) and post-process characterization (SEM, XRD, particle sizing) to quantify how torch geometry and operating parameters govern plasma structure, particle thermal histories, and final morphology. Relative to a conventional cylindrical RF–ICP torch at the same RF power (15 kW), the conical design reduces total gas consumption by 25–50%, increases volumetric power density by ∼13%, extends the axial high-temperature zone by ∼27%, and increases particle residence time in the effective heating region by ∼70%, thereby strengthening particle–plasma coupling and widening the operating window for complete melting. Parametric trends show that spheroidization improves with increasing RF power, whereas excessive carrier-gas flow and high powder feed rates reduce melting efficiency through plasma cooling and reduced residence time. Experimental measurements and microstructural analyses validate numerical predictions and demonstrate highly spherical alumina particles under optimized conditions with narrow morphological distributions. The role of carrier-gas composition is further examined: nitrogen enhances particle heating and spheroidization relative to argon and enables controlled formation of hollow alumina spheres. Cross-sectional analyses (ion milling/FIB-SEM) show uniform shell thicknesses of ∼1.5–2.5 μm, and size-based analysis indicates that hollow particles form predominantly from individual precursor particles rather than agglomeration. Overall, the conical RF–ICP torch provides an energy-efficient and versatile platform for advanced ceramic powder processing. [ABSTRACT FROM AUTHOR] |
| Copyright of Ceramics International is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
| FullText | Text: Availability: 0 |
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| Header | DbId: egs DbLabel: Engineering Source An: 194635216 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Development and experimental–Numerical investigation of alumina powder spheroidization and hollow sphere formation using a novel conical RF-ICP torch. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Ebrahimi%2C+Ali%22">Ebrahimi, Ali</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Alavi%2C+Sina%22">Alavi, Sina</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Mostaghimi%2C+Javad%22">Mostaghimi, Javad</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> javad.mostaghimi@utoronto.ca</i> – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Ceramics+International%22">Ceramics International</searchLink>. Jul2026, Vol. 52 Issue 17, p32290-32307. 18p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Plasma+materials+processing%22">Plasma materials processing</searchLink><br /><searchLink fieldCode="DE" term="%22Ceramic+powders%22">Ceramic powders</searchLink><br /><searchLink fieldCode="DE" term="%22Plasma+jets%22">Plasma jets</searchLink><br /><searchLink fieldCode="DE" term="%22Magnetohydrodynamics%22">Magnetohydrodynamics</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: A novel conical radio-frequency inductively coupled plasma (RF–ICP) torch is developed and systematically evaluated for alumina powder spheroidization. Magnetohydrodynamic (MHD) simulations coupled with discrete particle tracking are integrated with in-flight diagnostics (DPV-2000) and post-process characterization (SEM, XRD, particle sizing) to quantify how torch geometry and operating parameters govern plasma structure, particle thermal histories, and final morphology. Relative to a conventional cylindrical RF–ICP torch at the same RF power (15 kW), the conical design reduces total gas consumption by 25–50%, increases volumetric power density by ∼13%, extends the axial high-temperature zone by ∼27%, and increases particle residence time in the effective heating region by ∼70%, thereby strengthening particle–plasma coupling and widening the operating window for complete melting. Parametric trends show that spheroidization improves with increasing RF power, whereas excessive carrier-gas flow and high powder feed rates reduce melting efficiency through plasma cooling and reduced residence time. Experimental measurements and microstructural analyses validate numerical predictions and demonstrate highly spherical alumina particles under optimized conditions with narrow morphological distributions. The role of carrier-gas composition is further examined: nitrogen enhances particle heating and spheroidization relative to argon and enables controlled formation of hollow alumina spheres. Cross-sectional analyses (ion milling/FIB-SEM) show uniform shell thicknesses of ∼1.5–2.5 μm, and size-based analysis indicates that hollow particles form predominantly from individual precursor particles rather than agglomeration. Overall, the conical RF–ICP torch provides an energy-efficient and versatile platform for advanced ceramic powder processing. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Ceramics International is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1016/j.ceramint.2026.05.269 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 18 StartPage: 32290 Subjects: – SubjectFull: Plasma materials processing Type: general – SubjectFull: Ceramic powders Type: general – SubjectFull: Plasma jets Type: general – SubjectFull: Magnetohydrodynamics Type: general Titles: – TitleFull: Development and experimental–Numerical investigation of alumina powder spheroidization and hollow sphere formation using a novel conical RF-ICP torch. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Ebrahimi, Ali – PersonEntity: Name: NameFull: Alavi, Sina – PersonEntity: Name: NameFull: Mostaghimi, Javad IsPartOfRelationships: – BibEntity: Dates: – D: 05 M: 07 Text: Jul2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 02728842 Numbering: – Type: volume Value: 52 – Type: issue Value: 17 Titles: – TitleFull: Ceramics International Type: main |
| ResultId | 1 |
