Efficient and Safe Preparation of Al-based Metastable Intermolecular Composites: A High-Throughput Synthesis Strategy via Liquid-Phase Jet Fragmentation Method

To address the bottlenecks of inferior morphology associated with spray drying, inadequate safety of electrostatic spraying, and low efficiency of microfluidic technology in the preparation of Al-based MICs, the present study innovatively proposes a liquid-phase jet fragmentation synthesis strategy and establishes a liquid-liquid phase reaction device. Adopting the technical route of CFD simulation verification followed by experimental preparation, we fabricated Al-based MIC microspheres and systematically characterized their properties. Results demonstrate that the device exhibits rational flow field distribution and outstanding flow field stability, with its granulation efficiency being significantly superior to that of conventional microfluidic technology. The as-prepared microspheres feature regular morphology, uniform particle size, as well as excellent thermal performance. The liquid-phase jet fragmentation technology proposed in this study breaks through the core limitations of traditional preparation methods, providing an effective technical solution for the high-throughput, high-safety, and large-scale production of Al-based MICs, and laying a solid theoretical and experimental foundation for their practical applications. • A liquid-phase jet fragmentation synthesis strategy combined with a liquid-liquid phase reaction device is proposed to overcome the drawbacks of conventional methods for Al-based MICs. The device abandons electrostatic effects and relies on aqueous-phase hydrodynamic forces for propulsion, achieving high safety and avoiding channel clogging issues of microfluidic systems. • Verified by CFD simulation and experimental characterization, the developed device exhibits rational flow field distribution and excellent stability, with granulation efficiency significantly higher than that of traditional microfluidic technology. The synthesized Al-based MICs feature regular spherical morphology, uniform particle size, and no obvious defects, consistent with simulation results.