A regime map for dry powder coating: the influence of material properties and process parameters

A numerical study is carried out to investigate the combined influence of material properties and process parameters on coating quality in a high shear mixer (specifically an FT4 Powder Rheometer) to construct a regime map. The Discrete Element Method (DEM) is employed to simulate a range of material properties (size, density, and surface energy) and process parameters (impeller speed and mixing time) via Design of Experiments (DoE). A robust regime map is proposed for prediction of dry coating performance based on dimensionless Stokes deformation number (Stdef) and granular Bond number (Bo). The regime map provides insight on the optimal range of material properties and process parameters to achieve high coating levels in a high-shear bladed mixer. Furthermore, the minimum energy required to achieve optimal coating performance as well as regions of poor coating quality due to guest detachment exacerbated by excessive energy input can be identified from the regime map, thus reducing wastage of energy and coating material required. The regime map enables the required mixing time for optimal coating to be determined so long as particle size distributions and surface energies are known.