Powder TechnologyPub Date : 2026-04-15Epub Date: 2026-01-28DOI: 10.1016/j.powtec.2026.122179
Yunzhen Jiang , Chang Liu , Jiahang Du , Huaqing Ma , Zihan Liu , Yongzhi Zhao
{"title":"CFD-DEM simulation of bubble dynamics and hydrodynamics in fluidized beds with louver baffles","authors":"Yunzhen Jiang , Chang Liu , Jiahang Du , Huaqing Ma , Zihan Liu , Yongzhi Zhao","doi":"10.1016/j.powtec.2026.122179","DOIUrl":"10.1016/j.powtec.2026.122179","url":null,"abstract":"<div><div>Fluidized beds are commonly used equipment in the chemical industry, but large bubbles might be generated, which lower the conversion efficiency and operational stability. To address this issue, internal components (<em>e.g.</em>, louver baffles) can be employed to improve fluidization performance. Considering that the interaction between louver baffles and fluidized particle flows is quite complex, and the deploy settings would greatly influence the fluidization, further understanding is needed. The objective of this study is to investigate the effects of baffle inclination angle and superficial velocity on bubble dynamics and hydrodynamics in fluidized beds equipped with multi-layer louver baffles using computational fluid dynamics coupled with the discrete element method (CFD-DEM). Simulation results reveal that increasing superficial velocity in the baffle-free bed aggravates slug formation and deteriorates particle mixing. In contrast, the introduction of louver baffles effectively promotes bubble breakup and suppresses these phenomena, reducing the maximum average equivalent bubble diameter from approximately 140 mm to 31 mm. Baffles with 45° inclination generate the most uniformly distributed small spherical bubbles. As the inclination angle increases, particle downward motion becomes more pronounced, which induces local dilute regions and leads to an increase in bubble size. Notably, at low superficial velocities, steeper baffles with inclination angles of 55° and 60° may instead induce increased instability in the fluidized bed. These findings provide guidance for the design and optimization of baffled fluidized beds.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"473 ","pages":"Article 122179"},"PeriodicalIF":4.6,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146076472","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2026-04-15Epub Date: 2026-01-29DOI: 10.1016/j.powtec.2026.122203
Wanxuan Cai, Reiji Noda
{"title":"Mass transfer and energy analysis of polyethylene pyrolysis in a J−/L-type dual loop seal ICFB system","authors":"Wanxuan Cai, Reiji Noda","doi":"10.1016/j.powtec.2026.122203","DOIUrl":"10.1016/j.powtec.2026.122203","url":null,"abstract":"<div><div>Polyethylene (PE) pyrolysis was conducted at 550–650 °C in a bench-scale, three-compartment internally circulating fluidized bed (ICFB) equipped with a bulkhead-mounted dual loop seal integrating J- and L-type configurations. Gas yield increased from 55.10 wt% to 85.73 wt%, while the oil yield decreased from 43.73 wt% to 12.76 wt%, and char yield remained nearly constant at 1.00 wt%. Using our previously developed pressure-balance mathematical model of the J-type loop seal, which employs the bed height difference <span><math><mfenced><mrow><mo>∆</mo><mi>h</mi></mrow></mfenced></math></span> as the key parameter, particle transport rates <span><math><mfenced><mi>Gs</mi></mfenced></math></span> were predicted and applied to analyze the heat distribution and energy requirements for pyrolysis. The results revealed that under 550–650 °C, the heat required for pyrolysis ranged from 2.42 to 4.08 MJ/kg-PE. Approximately 9–14% of the heat generated in the combustor <span><math><mfenced><msub><mi>η</mi><mi>comb</mi></msub></mfenced></math></span> could be recovered and transferred to the pyrolizer, corresponding to 14–30% of the pyrolizer heat demand <span><math><mfenced><msub><mi>η</mi><mi>rep</mi></msub></mfenced></math></span>. Additionally, fluctuations in the pyrolizer backpressure could lead to particle circulation imbalance. These findings provide guidance for optimizing particle circulation and enhancing heat transfer in ICFB-based pyrolysis system.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"473 ","pages":"Article 122203"},"PeriodicalIF":4.6,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185604","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2026-04-15Epub Date: 2026-01-28DOI: 10.1016/j.powtec.2026.122211
Zhuang Liu , Bingyou Jiang , Yu Zhou , Gaochao Pan , Yunfan Wang , Yi Zhang , Chang-Fei Yu , Lei Gan , Jie Wang
{"title":"Preparation and dust suppression performance of a chitosan-based composite dust suppressant for mining applications","authors":"Zhuang Liu , Bingyou Jiang , Yu Zhou , Gaochao Pan , Yunfan Wang , Yi Zhang , Chang-Fei Yu , Lei Gan , Jie Wang","doi":"10.1016/j.powtec.2026.122211","DOIUrl":"10.1016/j.powtec.2026.122211","url":null,"abstract":"<div><div>The objective of this research was to formulate an eco-friendly composite dust suppressant for alleviating the detrimental impacts of coal mine dust on both workers' health and the surrounding environment. Using the natural polymer chitosan as a matrix, molecular modification was performed by grafting acrylamide (AM) to prepare modified chitosan (CS-g-AM) with low viscosity and high hydrophilicity. This modified chitosan was compounded with green surfactants and inorganic salt-based water-retaining agents to develop a composite dust suppressant integrating wetting, water retention, and binding functions. The optimal formulation was determined through surface tension, contact angle, water retention, and viscosity experiments. The microstructure, pore characteristics, dynamic wetting behavior, and dust suppression performance of the composite suppressant were systematically evaluated and compared with those of pure water and the traditional surfactant SDBS. The results demonstrated that the composite suppressant significantly improved the solidification effect on the coal dust surface, increased pore size and connectivity, enhanced water migration and adsorption capacity, and effectively reduced both the dust generation rate and the proportion of respirable dust during the cutting process. This study provides a theoretical basis and technical support for the development of green dust suppression materials in coal mining.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"473 ","pages":"Article 122211"},"PeriodicalIF":4.6,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185699","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Strengthening mechanism of the limonitic laterite sintering process through flux divided addition","authors":"Xuhui Lin , Xiaowen Liu , Xiangdong Xing , Penghui Guo , Yongqi Feng , Yize Ren , Haoxuan Chen , Donghui Wei","doi":"10.1016/j.powtec.2026.122184","DOIUrl":"10.1016/j.powtec.2026.122184","url":null,"abstract":"<div><div>Limonitic laterite contains abundant high-melting-point minerals and exhibits a high loss on ignition (LOI), which results in poor sintering suitability and low utilization efficiency. This study investigated the strengthening mechanism of sintering performance by adjusting the distribution of flux particles in mixture pellets. Sinter pot tests were conducted with varying flux divided-addition ratios to optimize the sintering process. With 30% flux divided addition, the vertical sintering speed, tumble index, reduction degradation index, and yield increased by 3.02 mm / min, 4.06%, 2.33%, and 2.26% respectively, while solid fuel consumption decreased by 11.00 kg / t and the reduction index decreased by 2.37% compared with the case without flux divided addition. Micromorphology and elemental composition analyses revealed that the flux divided addition method refined the microstructure of the limonitic laterite sinter. The thin-walled structures of the sinter diminished, the average pore size decreased from 64.09 μm to 45.00 μm, and silico-ferrite of calcium and aluminum (SFCA) formation increased. These findings demonstrate that the flux divided addition method is an effective strategy to improve the sintering performance of limonitic laterite.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"473 ","pages":"Article 122184"},"PeriodicalIF":4.6,"publicationDate":"2026-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185863","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2026-04-01Epub Date: 2025-12-22DOI: 10.1016/j.powtec.2025.122059
Chen Xing , Guo Zhengqi , Zhu Deqing , Pan Jian , Li Siwei , Yang Congcong
{"title":"Consolidation mechanism of oxidized pellets with composite laterite nickel ores","authors":"Chen Xing , Guo Zhengqi , Zhu Deqing , Pan Jian , Li Siwei , Yang Congcong","doi":"10.1016/j.powtec.2025.122059","DOIUrl":"10.1016/j.powtec.2025.122059","url":null,"abstract":"<div><div>As one of the main sources of ferronickel, laterite nickel ore faces the challenge of efficient utilization, mainly because of its complex chemical composition derived from diverse ore types. In this study, an innovative approach of mixing three different types of laterite nickel ores for pelletizing and roasting was proposed. The effects of basicity and roasting temperature on pellet mechanical strength were systematically investigated. The consolidation mechanism was revealed from multiple perspectives, including phase composition, porosity, microcracks, and liquid phase formation, and the evolution of nickel-bearing phases was also clarified. The results show that the pellets achieved optimal strength when the basicity was 0.2 and the roasting temperature was 1275 °C. This was mainly attributed to the formation of diopside, which lowered the melting point, decreased the porosity and promoted densification of the pellet structure. However, excessive basicity led to much more liquid phase generation, and abundant microcracks, thereby reducing the pellet strength. In addition, an appropriate amount of CaO destroyed the structure of augite, released the nickel contained therein, enhanced nickel enrichment, and facilitated the subsequent reduction process.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"472 ","pages":"Article 122059"},"PeriodicalIF":4.6,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146035744","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2026-04-01Epub Date: 2026-01-12DOI: 10.1016/j.powtec.2026.122138
Huili Huang , Zhongshun Sun , Chunyu Cheng , Gen Liu , Liyuan Fan , Bolun Yang , Chen Song , Zhiqiang Wu
{"title":"Enhanced hydrogen production via in-situ chemical looping reforming of fast pyrolysis volatiles from microalgae","authors":"Huili Huang , Zhongshun Sun , Chunyu Cheng , Gen Liu , Liyuan Fan , Bolun Yang , Chen Song , Zhiqiang Wu","doi":"10.1016/j.powtec.2026.122138","DOIUrl":"10.1016/j.powtec.2026.122138","url":null,"abstract":"<div><div>Hydrogen production via in-situ chemical looping reforming of rapidly pyrolyzed volatiles from microalgae was investigated using a NiFe<sub>2</sub>O<sub>4</sub>@SBA-15 oxygen carrier (OC). A two-stage fixed-bed reactor system was first employed to identify optimal pyrolysis conditions for chlorella and then to systematically optimise key reforming process parameters, including the confinement strategy, temperature, OC loading, and steam addition. The reaction pathway was further clarified using ex-situ characterisation techniques, providing detailed insight into intermediate species and structural changes during the process. Results showed that hydrogen and carbon yields in the pyrolysis products increased progressively with temperature. Therefore, 600 °C was identified as the optimal condition, attributed to the abundance of hydrogen-rich volatile precursors, including hydrocarbons and light volatile species. During the reforming stage, the highest hydrogen production performance was achieved at 850 °C, with an oxygen carrier to biomass ratio of 1 g·g<sub>microalgae</sub><sup>−1</sup>, and a steam injection volume of 0.4 mL, maintaining excellent stability over ten redox cycles. Ex-situ characterisation revealed that the controlled lattice oxygen transfer in nickel ferrite effectively promoted the selective conversion of volatiles. However, the accumulation of aldehyde intermediates and the extensive removal of oxygenated species were identified as rate-limiting steps. This study elucidates the reaction mechanism of hydrogen production via chemical looping reforming of fast microalgae pyrolysis. It provides an important theoretical basis and technical reference for green and low-carbon production of hydrogen from algal biomass.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"472 ","pages":"Article 122138"},"PeriodicalIF":4.6,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146035833","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2026-04-01Epub Date: 2026-01-16DOI: 10.1016/j.powtec.2026.122154
Zheng Yu , Baolei Liu , Liang Zhao , Cunyou Zou
{"title":"Numerical simulation study on particle migration and clogging behavior in typical pore-throat structures based on the resolved CFD-DEM method","authors":"Zheng Yu , Baolei Liu , Liang Zhao , Cunyou Zou","doi":"10.1016/j.powtec.2026.122154","DOIUrl":"10.1016/j.powtec.2026.122154","url":null,"abstract":"<div><div>Particle migration and clogging in porous media significantly impact reservoir development and groundwater remediation. However, systematic comparisons of typical pore-throat structures and their influence on particle dynamics remain insufficient. This study employs a fully resolved CFD-DEM-IBM framework integrated with dynamic mesh refinement to simulate particle transport and clogging in three representative pore-throat geometries: constricted, bifurcated, and large-pore throats. Results show that, in constricted pore throat, the propensity for clogging is primarily governed by the particle-to-throat size ratio and the hydrodynamic conditions, with a clear transition observed from free migration to intermittent and finally stable clogging as particle size increases. For bifurcated pore throat, clogging in the narrower branch induces significant flow redistribution and markedly alters the local pressure field. Within large pore throat, particle accumulation leads to complex internal flow patterning and can ultimately result in throat clogging. The proposed model accurately captures clogging dynamics and provides a reference for predicting particle migration and clogging behavior in complex porous media.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"472 ","pages":"Article 122154"},"PeriodicalIF":4.6,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146035831","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2026-04-01Epub Date: 2026-01-13DOI: 10.1016/j.powtec.2026.122147
Xianzheng Lu , Zhizhou Guo , Xiaojie Zhou , Jian Zhang , Xiaomin Chen , Xiaotong Pang , Yan Li , Chiping Lai , Luenchow Chan
{"title":"Deformation behavior and corrosion resistance of bio-inspired porous Ti-6Al-4V implants fabricated by selective laser melting","authors":"Xianzheng Lu , Zhizhou Guo , Xiaojie Zhou , Jian Zhang , Xiaomin Chen , Xiaotong Pang , Yan Li , Chiping Lai , Luenchow Chan","doi":"10.1016/j.powtec.2026.122147","DOIUrl":"10.1016/j.powtec.2026.122147","url":null,"abstract":"<div><div>Radially graded porous implants mimic natural bone's multi-level structure by precisely tailoring porosity distributions to address complex mechanical demands in bone grafting. This study thus designed three types of radially graded bio-inspired porous Ti-6Al-4 V (TC4) implants (i.e.: Gyroid, Diamond, and Schwarz structures) with approximately 63% average porosity based on triply periodic minimal surfaces (TPMS), and fabricated via selective laser melting (SLM). Their deformation behaviors, mechanical properties, and corrosion resistance were systematically investigated using finite element analysis (FEA), compression testing, and electrochemical measurements. FEA results revealed that under compression, Gyroid and Diamond structures undergo cyclic deformation involving elastic yielding followed by progressive layer-by-layer fracture, whereas the Schwarz structure behaved similarly to brittle lattices, exhibiting a cycle of elastic yielding and bulk fracture of entire layers, eventually leading to gradual densification. These findings aligned with experimental observations: Gyroid suppressed delamination fracture through diagonal struts, Diamond showed progressive layer-by-layer compaction, and Schwarz underwent brittle collapse. The straight-through channels formed in Schwarz's orthogonal strut network (compared to the spiral/oblique channels of Gyroid/Diamond) facilitated uniform simulated body fluid (SBF) permeation and full surface coverage. This promoted the homogeneous formation of passive film, yielding superior long-term corrosion resistance (<em>R</em><sub><em>ct</em></sub> of 351.2 kΩ·cm<sup>2</sup> after 12 days immersion). In contrast, Diamond's high pore connectivity led to weakened corrosion resistance. Overall, the Schwarz structure demonstrated the closest elastic modulus to natural bone (2.25 GPa), the highest yield strength (203 MPa), and the lowest corrosion rate (1.62 × 10<sup>−5</sup> mm·year<sup>−1</sup>), satisfying both mechanical and corrosion resistance requirements for bone implants.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"472 ","pages":"Article 122147"},"PeriodicalIF":4.6,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145975574","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2026-04-01Epub Date: 2026-01-14DOI: 10.1016/j.powtec.2026.122152
Guangting Xiong , Shaocheng Ge , Shuo Liu , Weizhi Zhao , Liying Sun , Xingyu Pang
{"title":"Magnetoelectric synergy enhances droplet wetting and capture of respirable hydrophobic coal dust: Mechanisms and suppression performance","authors":"Guangting Xiong , Shaocheng Ge , Shuo Liu , Weizhi Zhao , Liying Sun , Xingyu Pang","doi":"10.1016/j.powtec.2026.122152","DOIUrl":"10.1016/j.powtec.2026.122152","url":null,"abstract":"<div><div>Magnetoelectric coupling technology shows considerable potential for dust pollution control, yet the wetting and adhesion mechanisms of magnetized charged droplets remain unclear. Using hydrophobic anthracite dust, this study combines experiments and numerical simulations to incorporate droplet–particle impact dynamics into a magnetoelectric-synergistic dust suppression framework. The macroscopic wetting performance and mesoscopic impact dynamics of magnetized charged droplets on coal-dust particles are investigated, and their adhesion behavior is evaluated under varying droplet–dust size ratios and relative impact velocities. The results show that magnetic–electric synergy substantially enhances droplet wettability and that an optimal set of coupling parameters exists. At 300 mT and 9 kV, the droplet surface tension decreases to 32.9 mN/m, the rebound of small droplets impacting coal dust is greatly reduced, and the surface-wetting behavior is improved, leading to a 1.4-fold increase in maximum spreading on coal-dust particles compared with ordinary water droplets. As droplet diameter increases, the impact velocity required for optimal wetting decreases. When the droplet–dust size ratio exceeds 2, most of the droplet volume makes little contribution to effective wetting and instead traps air within the liquid film, weakening liquid–dust adhesion. With increasing relative impact velocity, droplet spreading accelerates and secondary droplets are generated. When the relative impact velocity exceeds 24 m/s, the liquid–dust contact behavior shifts from surface contact to point contact, and droplet dynamics become nearly independent of the coal-dust properties. These findings provide mechanistic insights and design guidance for magnetoelectric-assisted dust suppression.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"472 ","pages":"Article 122152"},"PeriodicalIF":4.6,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146035832","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Morphological characterisation of particulate emissions from various welding techniques used in industrial environments","authors":"Rubal Dhiman , Abhishek Singh , Adarsh Prakash , Akshat Jain , Sachin D. Kore , Anirudha Ambekar , Thaseem Thajudeen","doi":"10.1016/j.powtec.2026.122156","DOIUrl":"10.1016/j.powtec.2026.122156","url":null,"abstract":"<div><div>Particulates emitted from industrial welding are a major occupational concern, as their size and morphology strongly influence exposure–response relationships and associated adverse health effects. We systematically characterise the effective density, monomer number (N<sub>p</sub>), primary particle size (a<sub>p</sub>), shape factor (χ), and fractal dimension (D<sub>f</sub>) of particulates emitted from shielded metal arc welding (SMAW) and wire arc additive manufacturing (WAAM) under varying operating parameters using field-emission scanning electron microscopy (FE-SEM). A hybrid image analysis approach integrating optimisation techniques with FracVAL was used to reconstruct three-dimensional aggregate structures from two-dimensional FE-SEM images of welding particulates, for detailed morphological evaluation. The FE-SEM images from two welding techniques at different operating parameters revealed the presence of both spherical particles and fractal aggregates. WAAM mainly produced bare-like particles, whereas SMAW generated both bare and partially coated particles due to differences in operating principles. As particle mobility diameter increased during welding, the N<sub>p</sub> (10−220) and χ (1.5–1.8) increased, while effective density (5000–1000 kg/m<sup>3</sup>) decreased. During SMAW, higher welding current and sampling height increased D<sub>f</sub> (1.25–2.12) and polydispersity index (1.3–1.6), indicating progressively more compact particle structures. SMAW produced more compact aggregates (D<sub>f</sub>: 1.25–2.15) than WAAM (D<sub>f</sub>: 1.36–1.74). Morphological analysis indicates diffusion-controlled aggregation, with a mean D<sub>f</sub> value of ∼1.6, consistent with diffusion-limited cluster aggregation (DLCA) behaviour. These results provide crucial insights into how specific welding techniques influence particulate structure, underscoring the need to include the effect of particle shape as well in exposure studies and in tailoring control measures.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"472 ","pages":"Article 122156"},"PeriodicalIF":4.6,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146035835","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}