Effect of Dispersion Energy on Microparticle Entrapment in Non-Colloidal Systems

The ability to trap and deposit particles from flowing suspensions onto solid substrates underpins a wide range of technological applications, from coatings and sensors to biomedical devices and filtration systems. Entrapping particles from non-colloidal suspensions onto cylindrical substrates is governed by a competition between transport/impaction and adhesion/retention. We quantify “dispersion energy” (agitation intensity) via a normalized parameter and evaluate its effect on microparticle capture for low (Al) and high (Ni) density non-Brownian polydisperse particle suspensions. Image-based metrics (surface coverage, particle-transfer efficiency, size distributions) and spatial statistics (SOM, Voronoi tessellation and Delaunay triangulation) reveal a non-monotonic response: capture is maximized at intermediate dispersion energy where Stokes-number driven transport is sufficient for impaction, but impact energy and shear remain low enough for binder-mediated adhesion to arrest particles. At the range between Ψ ≈ 0.04 ×10-6-0.15×10-6 m5kg-1s-2, Al (lower specific density) reaches coverage 17.82 ± 17.40, while Ni (higher specific density) attains coverage 11.29 ±3.77. Size distributions are lognormal, narrowing with increasing as large-particle capture is suppressed. Spatial descriptors corroborate the mechanistic picture: near-optimal Ψ yields the most isotropic local packing; at higher Ψ, rebound and shear-induced sliding/rolling reduce adhesion; at lower Ψ, insufficient impaction limits capture. The framework-linking Ψ, impaction (via Stokes number), and adhesion thresholds-provides actionable guidance for tuning agitation to maximize entrapment in binder-assisted coatings, filtration preforms, and surface functionalization.