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The objectives of the Reactive Spraying division under the direction of Prof. Dr.-Ing. habil. Lutz Mädler include the design of spray processes that enable the synthesis of complex particulate materials through reactions in the gas and liquid phase. At the same time, the in-process processing of these materials is investigated (e.g. functionalization, mixing, coating) and the synthesis routes are linked to process optimization and design for specific application requirements.

Thus, the area of Reactive Spray Technology comprises the following research foci in theory and experiment:

  • Synthesis of functional nanoparticles and nanostructured surfaces
  • Preparation and characterization of disperse materials and porous layers
  • Reactor design and development for reactive spray applications for the synthesis of functional materials and layers
  • High-throughput methods and material-process data for experimental material development

Single-drop experiments are used to investigate the scientific basis of the mechanisms involved in the combustion of and explosion in single drops. In the established process of flame spray pyrolysis, organometallic fluids (precursors) are atomized into fine droplets in the first step, which react in a flame and synthesize into nanoparticles in the second step. A deep understanding of the processes and the interplay of atomization, reaction kinetics, nucleation, coagulation and condensation in multiphase flows is necessary for a tailor-made end product.

Multi-flame systems, which have been developed in the field in recent years, can be used to produce multicomponent systems in a targeted manner by synthesizing in two or more flames. The properties of the new material can be adjusted by defined interaction of the particles.

Many years of expertise in this field, starting with the conceptual idea and the reactor development, have made it possible to produce new materials and products that are used in catalysis, gas sensor technology, as multifunctional fillers (e.g. dental prostheses), optical materials and in flexible electronic coatings. These applications are always researched in theory and with simulations (DEM, DSMSC, CFD and corresponding couplings). In addition, the working group produces nanomaterials with defined properties and investigates their bio-nano interactions in numerous collaborations with research institutes and industry in Germany, Europe, USA and Australia.