processes

Article
Effects of Operating Parameters on the Cut Size of
Turbo Air Classifier for Particle Size Classification of
SAC305 Lead-Free Solder Powder
Nipon Denmud, Kradsanai Baite, Thawatchai Plookphol and Somjai Janudom *
Department of Mining and Materials Engineering, Faculty of Engineering, Prince of Songkla University, Hat
Yai 90112, Thailand
* Correspondence: Somjai.ja@psu.ac.th; Tel.: +66-7428-7065-6




Received: 21 May 2019; Accepted: 2 July 2019; Published: 5 July 2019


Abstract: In the present study, the effects of operating parameters, namely, rotor speed, feed rate, and
inlet air velocity, on the cut diameter of a cage-type separator were studied. The design of experiments
(DOE) method was used to investigate the relationship between the operating parameters and the
cut size. The experimental results were statistically analyzed using MINITAB 16 software. Both the
rotor speed and air inlet velocity had significant main effects on the cut size. The feed rate was also
significant but had a weak effect with respect to the rotor speed and inlet air velocity effects. The cut
size decreased with an increase in rotor speed and increased with an increase in air inlet velocity.
However, the cut size slightly decreased with an increase in feed rate. An empirical multiple-variable
linear model for predicting the cut size of the classification was created and presented. The results
derived from the statistical analysis were in good agreement with those from the experiments,
additionally extended from the DOE. The optimal conditions for classification of SAC305 powder
with size range 25–40 µm were obtained when the turbo air classifier was operated at rotor speed
406 RPM, the feed rate 4 kg/h, and the air velocity 5 m/s. The smallest cut size of the classifier was
about 27.8 µm.

Keywords: powder classification; turbo air classifier; cut size; SAC305; DOE

1. Introduction
SAC305 is one member of SAC (tin-silver-cooper) alloy family which is considered a lead-free
solder. It contains 96.5% Sn, 3% Ag, and 0.5% Cu. It has been accepted as the most promising due to its
relatively low melting temperature, good mechanical properties, and solderabilities [1], as well as its
superior creep properties [2]. In the reflow process of SAC alloys on Cu substrate, it leads to coarsening
of grains and further exhibits poor mechanical properties. However, a recent study has found that
the addition of the nanoparticle size of Fe and Al2 O3 in SAC solder alloys can improve mechanical
properties because of the formation of FeSn2 intermetallic compounds and Al2 O3 nanoparticles serving
as a grain refiner [3]. In the microelectronics packaging industry, SAC alloys are widely used as solder
pastes in connecting chip parts and ball grid arrays (BGAs) [4]. Lead-free solder powders which are
used in microelectronics applications strictly require high product qualities such as spherical shape,
low oxygen content (~100 ppm), and narrow size distribution [5]. Moreover, the particle size must
be suitable for the demand of the powder product. For instance, SAC305 powder (Type 3) with the
particle size range of 25–40 µm is generally considered as an industrial standard grade for producing
solder paste.
In the powder manufacturing industry, the classification process is regarded as one of the most
crucial operations which make the particle size of powder products meet the requirements of customers.

Processes 2019, 7, 427; doi:10.3390/pr7070427 www.mdpi.com/journal/processes

Processes 2019, 7, 427 2 of 16

Air classification is one of these techniques, in which the materials are classified using an air stream.
Recently, the dynamic-state air classifier has been developed to the third generation, i.e., the turbo air
classifier. Due to its high precision and good classification performance compared to its predecessors,
the turbo or cage-type separator has become one of the most popular kinds of equipment extensively
used for the preparation of powder in various industries, such as chemicals and metallurgy [6].
In addition, for the previous study in the mineral separation industry, for example, coal, the compound
dry separator was employed for removing mineral gangue from raw coal with +6 mm particle sizes.
Recently, the compound dry separator has been improved and can be used to classify fine coal powder
with −6 mm particle sizes [7]. Cut size (d50 : average particle size at 50% cumulative volume percentage)
of classification is an important factor with which to evaluate the performance of an air classifier. Thus,
it is a considerable concern when choosing a proper classifier for powder particle classification. The cut
size indicates the powder size at 50% of a partial separation efficiency curve; it mainly relies on the
structures of the classifier, material properties and operating parameters [8]. Many studies to improve
the structures of air classifiers, especially on the rotor cages, have been carried out. Wang et al. [9]
found that smaller cut sizes were obtained by making the inclining angle of rotor blades decrease.
Galk et al. [10] manufactured a new classifier rotor cage; higher sharpness of classification and an
excellent quality product of less than a micron were achieved. It has been reported in [11] that a sharper
classification was generally caused by higher air flow rates, together with a low feed rate. Recently,
many theoretical models have been proposed for predicting cut size; most cut size models have been
obtained using the fundamentals of aerodynamics, as reported by Wang et al. [12] and Lai et al. [13].
Under different assumptions for establishing a cut size formula, when the two forces (the drag force
and centrifugal force) are applied on a particle reaching an equilibrium at the external rim of the rotor
cage in the annular region, the cut size formula can be achieved [14]. Eswaraiah et al. [15] conducted
a theoretical determination of the performance of a classifier and proposed models for predicting
the sharpness and the cut size of classification. In addition, cut size may be calculated by using
the computational fluid dynamics (CFD) method, as previously reported by Huang et al. [16] and
Ren et al. [17].
During actual powder classification in the separation zone of an turbo air classifier, the motion
of particles inside this zone causes particle collision and agglomeration which affect the cut size,
leading to discrepancies between the calculated and experimental values. To predict the process
parameters affecting the powder classification performance, a multiple-variable nonlinear regression
technique is used for modelling an empirical formula to predict cut size. To obtain a reliable empirical
formula, many experimental runs and samples are required [18]. Thus, a suitable experimental design
is needed to evaluate the possible effects. A statistical design of experiments (DOE) technique can be
applied to obtain the effects of each parameter and their relative importance in a process. In addition,
the DOE provides the interaction effects of two or more variables as well [19]. To date, although many
studies have been carried out to optimize operating parameters affecting the performance of powder
classification by turbo air classifiers, most of these have been performed by using low-density powders
as feed materials, such as mica powder, calcium carbonate, quartz sand, fly ash, and talcum powder.
Few studies on turbo air classification using a high-density metal powder, such as SAC305 lead-free
solder powder (which has a density 7390 kg/m3 ) for feed materials, have been reported.
This study aims to investigate the effects of operating parameters of a turbo air classifier (a cage-type
air separator), namely, rotor speed, feed rate, and inlet air velocity, on the cut size (cut diameter) of
classification of SAC305 lead-free solder power. A full 23 -factorial design of experiments was employed
in this study. The results of the experiments were statistically analyzed using MINITAB 16 software
to identify the significant operating parameters affecting the cut size of classification. An empirical
multiple-variable linear model for predicting the cut diameter is also proposed in the study.
Processes 2019, 7, 427 3 of 16
Processes 2019, 7, x FOR PEER REVIEW 3 of 16

2. Materials
2. Materials and
and Methods
Methods

2.1. Materials
2.1. Materials
In this
In this study,
study, SAC305 powder was
SAC305 powder was manufactured
manufactured by by rotating
rotating disk
disk atomization
atomizationin inthe
thelaboratory.
laboratory.
After
After the SAC305 powder obtained was first screened by a 100-mesh standard laboratory sieve,
the SAC305 powder obtained was first screened by a 100-mesh standard laboratory sieve, this
this
powder was used as a feed material for turbo air classification experiments.
powder was used as a feed material for turbo air classification experiments. Powder from the Powder from the undersize
portion
undersize of portion
the sieve withsieve
of the particle
withsizes lesssizes
particle thanless
150than
µm150wasμmused
wasfor
usedthefor
experiments. The size
the experiments. The
distribution of the feed material, analyzed by a light scattering particle size analyzer,
size distribution of the feed material, analyzed by a light scattering particle size analyzer, is shown is shown in
Figure
in Figure1. 1.
The particle
The particlesize ofofthe
size thefeed
feedpowder
powderisisshown
showntotobe beapproximately
approximately50 μm. The
50µm. The SEM (JEOL
SEM (JEOL
model JSM-5800 LV, Tokyo, Japan) micrograph of the SAC305 feed powder
model JSM-5800 LV, Tokyo, Japan) micrograph of the SAC305 feed powder is shown in Figure 2. Theis shown in Figure 2. The
density of the SAC305 powder is 7390 kg/m 3 . For each experimental run, an approximate amount of
density of the SAC305 powder is 7390 kg/m3. For each experimental run, an approximate amount of
200 g
200 g of
of SAC305
SAC305 powder
powder was was fed
fed to
to the
the cage-type
cage-type separator.
separator.

Figure
Figure 1.
1. Particle
Particle size
size distribution
distribution of
of the
the SAC305
SAC305 feed
feed powder.
powder.

Figure 2. SEM
Figure 2. SEM micrograph
micrograph of
of SAC305
SAC305 lead-free
lead-free solder
solder powder,
powder, which
which was
was used
used as feed material
as feed material for
for
turbo air classification experiments.
Processes 2019, 7, x FOR PEER REVIEW 4 of 16

2.2. Experimental
Processes 2019, 7, 427 Procedure 4 of 16

In the present study, the air classifier used was fabricated in the laboratory of Prince of Songkla
University, Hat Yai,
2.2. Experimental Thailand to study cut size as affected by three operating parameters: rotor speed,
Procedure
feed rate, and air velocity. The schematic outline of the powder classification process is shown in
In the present study, the air classifier used was fabricated in the laboratory of Prince of Songkla
Figure 3. The system consisted of four main parts, namely, the vibratory feeder, the turbo air
University, Hat Yai, Thailand to study cut size as affected by three operating parameters: rotor speed,
classifier, the dust collector, and the centrifugal fan. The rotor speed of the classifier was measured
feed rate, and air velocity. The schematic outline of the powder classification process is shown
by a tachometer. The powder feed rate was controlled by adjusting the magnitude of vibration of a
in Figure 3. The system consisted of four main parts, namely, the vibratory feeder, the turbo air
vibratory feeder. The air inlet velocity was measured by a hot-wire anemometer. In the experiment,
classifier, the dust collector, and the centrifugal fan. The rotor speed of the classifier was measured
a SAC305 powder specimen was first fed by the vibratory feeder into the turbo air classifier via its
by a tachometer. The powder feed rate was controlled by adjusting the magnitude of vibration of a
feed inlet. Then, the feed powder gravitationally dropped onto the scatter plate of the cage rotor,
vibratory feeder. The air inlet velocity was measured by a hot-wire anemometer. In the experiment,
rotating at a high speed. The feed powder was flung outward and sunk into the cylindrical gab called
a SAC305 powder specimen was first fed by the vibratory feeder into the turbo air classifier via its feed
the annular area. The feed powder in this area was influenced by the centrifugal and drag forces.
inlet. Then, the feed powder gravitationally dropped onto the scatter plate of the cage rotor, rotating at
Under these different forces applied on the particle, if the centrifugal force is able to overcome the
a high speed. The feed powder was flung outward and sunk into the cylindrical gab called the annular
drag force, the powders are thrown outward to the wall of the classifier, after which they fall into the
area. The feed powder in this area was influenced by the centrifugal and drag forces. Under these
powder collector and are then collected as the coarse powder product. Otherwise, the particles are
different forces applied on the particle, if the centrifugal force is able to overcome the drag force, the
brought through the center of the cage rotor by the strong suction air stream created the centrifugal
powders are thrown outward to the wall of the classifier, after which they fall into the powder collector
fan, carried to the dust collector, and then collected as the fine powder product. After many
and are then collected as the coarse powder product. Otherwise, the particles are brought through the
classification experiments, both coarse and fine powder products were weighted. The powder
center of the cage rotor by the strong suction air stream created the centrifugal fan, carried to the dust
products were sampled for measuring particle size distribution by a light-scattered particle size
collector, and then collected as the fine powder product. After many classification experiments, both
analyzer. Using the particle size distributions (PSD) of feed, coarse, and fine products, a fractional
coarse and fine powder products were weighted. The powder products were sampled for measuring
recovery curve of the coarse product, a so-called Tromp curve was constructed using the equation
particle size distribution by a light-scattered particle size analyzer. Using the particle size distributions
proposed by Mejeoumov [20], i.e.,
(PSD) of feed, coarse, and fine products, a fractional recovery curve of the coarse product, a so-called
Tromp curve was constructed using the equationproposed f   by − f 3i 
f Mejeoumov [20], i.e.,
Tromp Curve =  2 i  ×  1i  (1)
 ff2i1i ! f1if 2−i −f3i f!3i 
Tromp Curve = × (1)
where f1i is the portion of the powders in the i-th fraction
f1i of
f2ithe
− f3ifeed powder, f2i is the portion of the
powders in the i-th fraction of the coarse powder, and f3i is the portion of the powders in the i-th
where f 1iofisthe
fraction thefine
portion of the powders in the i-th fraction of the feed powder, f 2i is the portion of the
powder.
powders in the i-th fraction
The cut size of classificationof the
wascoarse powder,
obtained fromand f 3i is the
the Tromp portion
curve. Theofrelationship
the powders i-th
in the the
between
fraction ofparameters
operating the fine powder.
and the cut sizes was further statistically examined using MINITAB 16.

Figure 3. Schematic outline of classification process used in this study. 1: vibratory feeder, 2: turbo air
Figure 3. Schematic outline of classification process used in this study. 1: vibratory feeder, 2: turbo
classifier, 3: dust collector, and 4: centrifugal fan.
air classifier, 3: dust collector, and 4: centrifugal fan.

The cut size of classification was obtained from the Tromp curve. The relationship between the
2.3. Experimental Design
operating parameters and the cut sizes was further statistically examined using MINITAB 16.
Processes 2019, 7, 427 5 of 16

2.3. Experimental Design

To reduce many experimental runs but still maintain accuracy of experimental results, a 23 -factorial
design was adopted for the present work. For a 2-level factorial design, the low and high levels are
specified as −1 and +1, respectively. The operating parameters, i.e., rotor speed, feed rate, and air inlet
velocity are coded A, B, and C at low and high levels, respectively, as shown in Table 1. These three
operating parameters were selected for experiments according to the reviewed literature [18,21] since
they are important process parameters which strongly affect the cut size of the cage-type air classifier
and can be strictly controlled and varied to different levels. Other parameters such as the type of rotor
and size of feed powder material were fixed. MINITAB (Version 16, Minitab Inc., State college, PA,
USA, 2010) was used to create a randomized full 23 -factorial design with two replications, without
the center point and blocking setting. The total number of designed experiments was 16, as shown in
Table 2. Column 1 of Table 2 is the randomized standard order of experiments. The experiments were
performed according to the run order in Table 2. Cut size results of 16 experiments are shown in the last
column of Table 2. These results were further used for statistical analysis, ANOVA, and linear regression
analysis for obtaining the connection between the cut diameter and the three operating parameters.

Table 1. Operating parameters and their levels.

Level
Parameters Parameter Name (unit)
Low (−1) High (+1)
A Rotor speed (RPM) 194 406
B Feed rate (kg/h) 4 27
C Air inlet velocity (m/s) 5 8.5

Table 2. The 23 -factorial experimental design with duplication and the results of cut size (d50 : average
particle size at 50% cumulative volume percentage) from the experiments.

Run Center (A) Rotor (B) Feed Rate (C) Air Inlet Cut Size
Std Order Blocks
Order Pt Speed (RPM) (kg/h) Velocity (m/s) (µm)
13 1 1 1 −1 −1 1 112.1
8 2 1 1 1 1 1 46.9
11 3 1 1 −1 1 −1 57.0
9 4 1 1 −1 −1 −1 66.7
4 5 1 1 1 1 −1 39.4
6 6 1 1 1 −1 1 63.8
12 7 1 1 1 1 −1 31.7
10 8 1 1 1 −1 −1 30.8
5 9 1 1 −1 −1 1 111.2
16 10 1 1 1 1 1 46.6
3 11 1 1 −1 1 −1 55.5
7 12 1 1 −1 1 1 117.9
1 13 1 1 −1 −1 −1 68.7
14 14 1 1 1 −1 1 72.2
15 15 1 1 −1 1 1 121.1
2 16 1 1 1 −1 −1 24.7

3. Results and Discussion

3.1. Statistical Analysis

The experimental results and cut sizes of classifications by turbo air classifier are shown in Table 2.
The 16 data were statistically analyzed using MINITAB 16 to determine the individual and interaction
effects between parameters, namely, rotor speed (A), feed rate (B), and air velocity (C). Because the
effect of each parameter represents a change in the response (i.e., the cut size), the response is affected
Processes 2019, 7, 427 6 of 16

by changing each parameter from a low to high level. The codified mathematical model for the 2-level
factorial design used in experiments is given by Equation (2) [22–24], i.e.,

d50 = β0 + β1 A + β2 B + β3 C + β12 AB + β13 AC + β23 BC + β123 ABC (2)

where d50 is the predicted response; A, B, and C represent the corresponding parameters in their
coded forms; β0 is the mean; β1 , β2 , and β3 are the linear coefficients; and β12 , β13 , β23 , and β123 are the
interaction coefficients.

3.2. Analysis of Variance

The sum of squares was employed to evaluate the effects of factors. Furthermore, the F-ratios
and the P-values from ANOVA are shown in Table 3. The statistically significant effects of the factors
were examined using P-values. It was found that the main effects (A, B and C), two-way interaction
(A × C) and three-way interaction (A × B × C) were statistically significant because the P-values from
the ANOVA test were less than the confidence limit (α = 0.05) at which the null hypothesis could be
rejected. However, the two-way interactions A × B and B × C were not significant.

Table 3. ANOVA for the cut size (d50 ).

Sources Degree of Freedom Sum of Squares Mean Squares F P

A: Rotor speed 1 7847.7 7847.75 674.86 0.000
B: Feed rate 1 72.9 72.89 6.27 0.037
C: Air inlet velocity 1 6292.9 6292.85 541.15 0.000
A×B 1 24.6 24.58 2.11 0.184
A×C 1 777.4 777.43 66.85 0.000
B×C 1 23.4 23.35 2.01 0.194
A×B×C 1 581.9 581.90 50.04 0.000
Pure error 8 93.0 11.63
Total 15 15,713.8

Table 4 shows the effects, the linear coefficients, the standard errors, the T-values, and the P-value
from the analysis of the 23 -factorial design of experiments. The main effects indicate average values for
each experimental run between a low level and high level. If the effect value of a parameter (in column
3 of Table 4) is positive, for example, the effect of air inlet velocity (C), it means that the cut size is
increased with increasing the air inlet velocity from a low to a high level. Inversely, if the effect value is
negative, for instance the effect of rotor speed (A), the cut size is decreased with increasing the rotator
speed from a low level to a high one. By substituting the coefficients of A, B, C, AB, AC, BC, and ABC
from Table 4 into Equation (2), we obtain a model equation for the cut size as follows:

d50 = 66.66 − 22.15A − 2.13B + 19.83C − 1.24AB − 6.97AC − 1.21BC − 6.03ABC (3)

When considering the p-values of the parameters shown in Table 4, the parameters are significant
if their p-value is less than the confidence limit α = 0.05; if their p-values are greater than 0.05, they are
not significant. It was found that the p-values of parameters AB and BC are greater than 0.05. The
parameters AB and BC can be discarded due to their insignificance. Hence, the cut size model in
Equation (3) can be reduced to Equation (4), as follows:

d50 = 66.66 − 22.15A − 2.13B + 19.83C − 6.97AC − 6.03ABC (4)

A normal probability plot of the standardized effects on cut size is shown in Figure 4. The graph
is used to identify the effect of the operating parameter, that is, whether it is statistically significant or
not significant. All calculated effects are plotted against a straight line which represents the normal
distribution line. The results show that the main effects A, B, and C and the interaction effects AC
 Table 4. Statistical parameters for 23-factorial design of experiments.

Standard Error
Terms Effects Coefficients T P
Coefficients
Processes 2019, Constant
7, 427 66.66 0.8525 78.19 0.000 7 of 16
A −44.29 −22.15 0.8525 −25.98 0.000
B −4.27 −2.13 0.8525 −2.50 0.037
and ABC stay away C from39 the
.66
normal distribution
19.83 line. Thus, the effects are
0.8525 23considered
.26 0.000 statistically
significant at the AB 5% significance
−2.46 level (α =
−1.24 0.05). Factors A and
0.8525 C have a stronger
−1.45 0effect
.184
on the cut
size since they AC both lie farther
−13.94 from the straight
−6.97 line. The effects0.8525of factors B,−8AC,
.18
and 0ABC
.000
are slightly
significant, since BC they are closer
−2.42 to the straight
−1.21 line. By contrast,
0.8525 factors AB and
−1.42 BC
0.194 two solid
(the
circles shown ABC in Figure 4)−12
are.06
not significant.
−6.03 0.8525 −7.07 0.000
S 3.41008
Table 4. Statistical parameters for 23 -factorial design of experiments.
R-Sq 0.9941
R-Sq (adj) Effects
Terms 0.9889 Coefficients Standard Error Coefficients T P
Constant 66.66 0.8525 78.19 0.000
A normalA probability plot of the−22.15
−44.29 standardized effects on cut size is shown −25.98
0.8525 in Figure0.000
4. The graph
is used to identify
B the −4.27
effect of the operating
−2.13 parameter, that is, whether it is statistically
0.8525 −2.50 significant
0.037
C . All calculated
or not significant 39.66 19.83
effects are plotted against a0.8525 23.26
straight line which represents 0.000
the normal
AB −2.46 −1.24 0.8525 −1.45 0.184
distribution line. The results show that the main effects A, B, and C and the interaction effects AC and
AC −13.94 −6.97 0.8525 −8.18 0.000
ABC stay away BC from −2.42
the normal distribution
−1.21 line. Thus,0.8525
the effects are considered
−1.42 statistically
0.194
significant at
ABCthe 5% significance
−12.06 level
−6.03(α = 0.05). Factors A and
0.8525 C have a stronger
−7.07 effect on the cut
0.000
size since they both lie farther from the straight line. The effects of factors B, AC, and ABC are slightly
S 3.41008
significant, R-Sq
since they 0.9941
are closer to the straight line. By contrast, factors AB and BC (the two solid
R-Sq (adj) 0.9889
circles shown in Figure 4) are not significant.

Figure 4. Normal probability plot of standardized effects for

for cut
cut size
size (at α = 0.05).
(at α

A Pareto chart of standardized effects on cut size size is

is shown
shown inin Figure
Figure 5. 5. The chart shows the
relative importance of the effects. The t-value is equal to 2.31, based on the 95% confidence level and
eight degrees of freedom. The
The vertical
vertical line on the chart represents the lowest statistical significance
of the effect. The
The individual
individual and
and interaction
interaction effects
effects with
with aa higher
higher value
value than than the
the reference line are
considered potentially
potentially important.
important. From
Fromthe
thePareto
Pareto chart
chart in
in Figure
Figure 5,
5, itit is
is seen
seen that
that the
the effects of the
factors A, C, AC, ABC, and B are significant, while the effects of AB
effects of and BC
AB and BC are
are not
not significant.
significant.
Processes
Processes 2019, 7, 427
2019, 7, x FOR PEER REVIEW 88 of
of 16
16
Processes 2019, 7, x FOR PEER REVIEW 8 of 16

Figure 5. Pareto chart of standardized effects for cut size (α = 0.05).

Figure 5. Pareto chart of standardized effects
effects for
for cut
cut size (α =
size (α = 0.05).
Figure 6 shows a main effect plot to indicate how the operating parameters of the separator affect
Figure
the cut 66 shows
diameter
Figure shows of aaclassification.
main effect
main effect plot
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rotor’s are steeper
rotation and airthan that of
velocity arethe feeding
steeper thanratethat
[25].of the feeding
rate [25].

Figure 6. Main
Main effects
effects plot for cut size.
Figure 6. Main effects plot for cut size.
The interaction effects of the operating parameters
parameters of the turbo air classifier on cut size areare shown
shown
in Figure 7. The interaction
The interaction
The interaction plot
effects ofplot represents
the represents the effect
the effect of
operating parameters of one
ofone parameter, which is dependent on the
the turbo air classifier on cut size are shown
level of another
in Figure 7. Theparameter.
interactionItplot
is seen that there
represents theare interactions
effect between rotor
of one parameter, whichspeed (A) and air
is dependent oninlet
the
velocity (C). Because
level of another the lines
parameter. ofseen
It is effects
thatAthere
and Care
areinteractions
likely to cross each other
between rotor (they
speedare(A)not
andparallel),
air inlet
velocity (C). Because the lines of effects A and C are likely to cross each other (they are not parallel),
Processes 2019, 7, 427 9 of 16

Processes 2019, 7, x FOR PEER REVIEW 9 of 16

velocity (C). Because the lines of effects A and C are likely to cross each other (they are not parallel),
these
these two
two factors
factors are
are considered
considered to to interact
interact with
with each
each other
other significantly
significantly [26]. This means
[26]. This that at
means that at the
the
low
low air
air velocity of 55 m/s,
velocity of m/s, the
the decrease
decrease in in cut
cut size
size was about 30
was about 30 μm,
µm, from
from 62.0 to 31.7
62.0 to μm, when
31.7 µm, when thethe
rotor speed was increased from 194 to 406 RPM. However, at the higher inlet air velocity
rotor speed was increased from 194 to 406 RPM. However, at the higher inlet air velocity of 8.5 m/s, of 8.5 m/s,
the
the change
change in in speed
speed ofof the
the cage-type
cage-type rotor
rotor from
from 194
194 to
to 406
406 RPM
RPM waswas able
able to
to decrease the cut
decrease the cut size
size by
by
58 μm, from
58 µm, from 115.6
115.6 to
to 57.4
57.4 µm. When the
μm. When the air
air velocity
velocity increased
increased from
from 55 m/s
m/s to
to 8.5
8.5 m/s,
m/s, the
the interactions
interactions
between A B, B and C,
between parameters A and B, as well as B and C, were not significant; the solid line and dotted
parameters and as well as were not significant; the solid line and the line
the dotted
are
linealmost parallel
are almost [26]. In
parallel addition,
[26]. the results
In addition, of the interaction
the results effects plot
of the interaction in Figure
effects 7 are
plot in consistent
Figure 7 are
with those results previously presented in Table 4 in which the interactions AB and BC
consistent with those results previously presented in Table 4 in which the interactions AB and BC had had the p-values
higher than 0.05
the p-values (>95%
higher thanconfidence
0.05 (>95%limit).
confidence limit).

Figure 7. Interaction effects plot for cut size.

3.3. Experimental Verification

3.3. Experimental Verification
In
In order
order to toconfirm
confirmthe theresults
resultsfrom
fromthetheDOE,
DOE,additional turbo
additional air classification
turbo experiments
air classification experimentswere
carried out on the SAC305 powder at the high rotor speed of 619 RPM by
were carried out on the SAC305 powder at the high rotor speed of 619 RPM by varying the air inlet varying the air inlet velocities
to 5, 6.5, and
velocities to 5,8.5 m/s.
6.5, andFigure
8.5 m/s. 8 shows
Figure a8 comparison of cut size
shows a comparison offrom experiments
cut size performed
from experiments at rotor
performed
speeds
at rotor197,
speeds408,197,
and408,
619 RPM,
and 619 and at airand
RPM, velocities 5, 6.5, and
at air velocities 5, 8.5
6.5,m/s,
andusing a fixed
8.5 m/s, using feed rate of
a fixed 4 kg/h.
feed rate
It is seen that the cut size is obviously affected by the speed of the cage rotor
of 4 kg/h. It is seen that the cut size is obviously affected by the speed of the cage rotor and the inlet and the inlet velocity.
In other words,
velocity. In otherthe cut size
words, the decreases with higher
cut size decreases withrotational speed; however,
higher rotational it increases
speed; however, with an
it increases
increase in air inlet
with an increase in velocity, which is consistent
air inlet velocity, with the results
which is consistent with the from the DOE
results fromanalysis.
the DOE Guo et al.Guo
analysis. [14]
found that when the rotor speed increased, velocity in the separation zone would
et al. [14] found that when the rotor speed increased, velocity in the separation zone would be affected be affected because
this factor
because caused
this factor a decrease
caused ain the radial
decrease in velocity
the radialand an increase
velocity and anin the tangential
increase in thevelocity,
tangentialcontributing
velocity,
to the higher centrifugal force applied to the particles and consequently
contributing to the higher centrifugal force applied to the particles and consequently a decrease a decrease in the cut size.
in
Theoretically, increasing the rotational velocity of the rotor cage causes
the cut size. Theoretically, increasing the rotational velocity of the rotor cage causes a strong a strong centrifugal force
which is applied
centrifugal force to the particles.
which is applied Thetolarge particles are
the particles. Thethrown outwardare
large particles by the centrifugal
thrown outward force
by and
the
are
centrifugal force and are moved downward and dropped into the collector tank at the bottomcoarse
moved downward and dropped into the collector tank at the bottom of the classifier as a of the
powder
classifierproduct,
as a coarse resulting
powder in aproduct,
decreaseresulting
in cut size.
in aWith increasing
decrease in cutinlet
size.air velocity,
With the drag
increasing force
inlet air
of the air stream acting on the particles increases. Some large and small
velocity, the drag force of the air stream acting on the particles increases. Some large and small particles will be carried to
the center of the cage-type rotor by the upward airflow and will be
particles will be carried to the center of the cage-type rotor by the upward airflow and will be collected in the dust collector
chamber
collected as in athe
fine
dustpowder product.
collector chamberThisas results
a fineinpowder
the increase of the
product. Thiscutresults
diameter of classification
in the increase of the of
cut diameter of classification of the cage-type air separator [21]. In the present work, it was noted that
for the experiments performed at the rotational velocity of 619 RPM and at the air inlet velocities of
5 and 6.5 m/s, the Tromp curves of classification calculated using Equation (1) cannot be constructed
Processes 2019, 7, 427 10 of 16

the cage-type air separator [21]. In the present work, it was noted that for the experiments performed
at the rotational
Processes velocity
2019, 7, x FOR of 619 RPM and at the air inlet velocities of 5 and 6.5 m/s, the Tromp curves
PEER REVIEW 10 of of
16
classification calculated using Equation (1) cannot be constructed to obtain the cut size since at too
to obtain
high an airthe cutvelocity
inlet size since
theat tooforces
two high acting
an air on
inlet
thevelocity
particlesthe
aretwo
veryforces acting
different. on the
Using theparticles are
rotor speed
veryRPM,
619 different. Using
air inlet the rotor5 speed
velocities and 6.5 619
m/sRPM,
can air inletan
cause velocities
excessive5 and 6.5 m/s can
centrifugal cause
force. an excessive
In the turbo air
centrifugaltheforce.
classifier, In theforce
centrifugal turbo air classifier,
is required the centrifugal
for powder force is
size separation. Therequired
magnitudefor of
powder size
centrifugal
separation.
force depends Theonmagnitude of centrifugal
the rotor speed force depends
and the particle on the rotor
size of powder. speedparticles
The large and theare
particle
acted size
by the of
powder. The large particles are acted by the strong centrifugal force field. They
strong centrifugal force field. They are immediately thrown outside the annular gap of the air classifier are immediately
thrown
and outside
collected the coarse
as the annular gap of[14].
product the air classifier
Under and collectedconditions
these experimental as the coarse product
in this study,[14].
mostUnder
of the
these experimental
powder was collected conditions in this
as the coarse study, most
product. Very of the amount
small powder of was collected
fine particlesaswas
the collected
coarse product.
by the
Verycollector
dust small amount of product.
as the fine fine particles was collected
Consequently, these twoby products
the dustwere collector as the fine
not effectively product.
separated by
Consequently,
the classifier. these two products were not effectively separated by the classifier.

5,
Figure 8. Plot of cut size against rotor speed for the experiments performed at air inlet velocities of 5,
6.5, and 8.5 m/s and a feed rate of 4 kg/h (of note is that for the results at rotor speed 619 RPM and air
inlet velocities 5 and 6.5 m/s, the Tromp
Tromp curves of classification used for evaluating cut size could not
be constructed—see explanation in the the text).
text).

Figure
Figure 99 shows
shows the
the relationship
relationship between
between cutcut size
size and
and air
air inlet
inlet velocity
velocity for
for the
the experiments
experiments
performed at two constant rotor speeds of 194 RPM and 406 RPM at a fixed feed
performed at two constant rotor speeds of 194 RPM and 406 RPM at a fixed feed rate of 4 kg/h.rate of 4 kg/h. It can be
It can
clearly seen that with increasing inlet air velocity of the separator the cut size becomes
be clearly seen that with increasing inlet air velocity of the separator the cut size becomes coarser. coarser. Since
at a higher
Since air inletair
at a higher velocity the air stream
inlet velocity the airflowing
streamupward
flowingwill act onwill
upward the particles
act on the more intensively,
particles more
the coarse particles will be moved together with the fine particles and collected in the
intensively, the coarse particles will be moved together with the fine particles and collected in the dust collector
chamber as a fine
dust collector powder
chamber as aproduct. This product.
fine powder brings about
Thisincreasing
brings aboutcutincreasing
size. The results inThe
cut size. Figure 9 also
results in
confirm that the cut sizes obtained from the experiments performed at high rotor speed
Figure 9 also confirm that the cut sizes obtained from the experiments performed at high rotor speed (406 RPM) are
smaller
(406 RPM)than
arethose using
smaller thethose
than low rotor
usingspeed
the low(194 RPM).
rotor speed (194 RPM).
Processes 2019, 7, 427 11 of 16
Processes 2019, 7, x FOR PEER REVIEW 11 of 16

Figure 9.
9. Plot
Plot cut size against air inlet velocity from the experiments performed at constant rotor
RPM and
speeds of 194 and 406 RPM and feed
feed rate
rate 44 kg/h.
kg/h.

From
From the thepresent
presentexperimental
experimental results
resultsit can be discerned
it can be discerned that thethatrotor
the speed
rotor andspeed air and
inlet air
velocity
inlet
have
velocitya stronger
have a impact
stronger onimpact
the cuton diameter
the cutof the cage-type
diameter of the separator
cage-typethan the feeding
separator than the rate.feeding
Additionalrate.
experiments were performed by extending the rotor speed to
Additional experiments were performed by extending the rotor speed to the third level of 619 RPMthe third level of 619 RPM at inlet air
velocities
at inlet airof 8.0, 6.5, of
velocities and8.0,5.0 m/s,
6.5, andas5.0presented in Figurein
m/s, as presented 8. Figure
It was8.foundIt wasthatfoundat athat
fixedat feed
a fixedratefeedof
4rate
kg/h ofand air velocity
4 kg/h and air 8.5 m/s, a8.5
velocity cutm/s,
diameter
a cutofdiameter
42 µm was obtained.
of 42 μm was However,
obtained.forHowever,
the experiments
for the
at air velocities
experiments of 6.5
at air m/s andof5.0
velocities 6.5m/s,
m/stheand separations
5.0 m/s, the were not complete,
separations were and the cut size
not complete, could
and the not
cut
be
sizedetermined
could not be from the Tromp
determined curves.
from The cut
the Tromp size, at
curves. The a fixed rotor
cut size, atspeed
a fixedofrotor
406 RPMspeedand air RPM
of 406 inlet
velocity
and air inlet6.5 m/s, was 41
velocity 6.5µm, which
m/s, was was41 μm,larger
whichthanwas the expected
larger than 30 the cut size. The
µm expected 30 μm smallest cut size,
cut size. The
27.8 µm, was
smallest achieved
cut size, fromwas
27.8 μm, the experiment
achieved from which theused a rotor speed
experiment whichof 406 aRPM
used rotorandspeedan inlet velocity
of 406 RPM
of
and5.0anm/s.
inletMoreover,
velocity ofat5.0air inlet
m/s. velocitiesat6.5
Moreover, airm/s
inletand 5.0 m/s6.5
velocities them/scutandsize5.0tended
m/s the tocut
decrease with
size tended
to decrease with increasing rotor speed. If a target cut size ≤30 μm is expected for turbo air
increasing rotor speed. If a target cut size ≤30 µm is expected for turbo air classification, the rotor
speed should be
classification, theincreased
rotor speed to a should
level between 406 and
be increased to619 RPM.
a level For further
between 406 study,
and 619 experiments
RPM. For furthershould
be focused
study, on rotor should
experiments speeds be 500focused
and 550on RPM
rotor tospeeds
achieve500 theand
target
550cutRPM size.
to achieve the target cut size.
Figure
Figure 10 10 displays
displaysthe theparticle
particlesize sizedistributions
distributionsofofthe theSAC305
SAC305powder powder forfor
thetheexperiments
experiments runrunat
two
at two different
different air air
inlet velocities,
inlet velocities,namely,
namely,6.5 6.5
m/sm/s andand8.5 m/s, using
8.5 m/s, the the
using same rotational
same rotational speedspeedof theof
cage typetype
the cage rotorrotor
619 RPM619 RPMand feed rate 4rate
and feed kg/h. In Figure
4 kg/h. 10a the
In Figure 10aparticle size distribution
the particle size distributioncurvescurves
of the
feed
of the andfeedfineandpowder productsproducts
fine powder are similar are(the curves
similar almost
(the curvesoverlap
almost each other) each
overlap but the particle
other) but size
the
distribution
particle size of the coarse of
distribution powder is different
the coarse powder from these two.
is different fromIf we consider
these two. Ifthewedconsider
50 of the feed
the dand
50 of fine
the
powder
feed andproducts,
fine powder theyproducts,
are almost theyequal. These results
are almost equal. indicate
These resultsthat the separation
indicate that the of separation
fine particles of
from the feed from
fine particles powder the was
feednot effectively
powder was notperformed.
effectivelyInperformed.
addition, this conditionthis
In addition, might be caused
condition mightby
collision
be causedand by agglomeration of powders during
collision and agglomeration of powders classification, leading to overlapping
during classification, leading to between
overlapping the
coarse
between and thefine products.
coarse and fine Theproducts.
phenomenon of particle agglomeration
The phenomenon generally results
of particle agglomeration from the
generally van
results
der
from Waals
the force
van acting
der Waalson theforce
fine particles
acting on [27].the Byfine
contrast, the particle
particles [27]. By sizecontrast,
distributions the in Figure size
particle 10b
for the experiment
distributions run at10b
in Figure air inlet
for thevelocity 8.5 m/s,run
experiment the at
curves of feed,
air inlet coarse,
velocity 8.5andm/s,fine
thepowder
curvesproducts
of feed,
are clearly
coarse, andseparated.
fine powder Thisproducts
means that areat the airseparated.
clearly inlet velocity This8.5 m/s, the
means thatfeed powder
at the wasvelocity
air inlet effectively 8.5
separated
m/s, the feed into fine and coarse
powder was power products.
effectively separatedIn fact,into
increasing
fine and the coarse
magnitude power of the air inlet velocity
products. In fact,
to a proper the
increasing value causes not
magnitude ofonly theinlet
the air increasing
velocity of to
cuta size
proper but value
also the helping
causes not of thethe
only feedincreasing
powders to of
be
cuteffectively
size but also classified owing
the helping of to
thethe
feedhigher
powders dragto force acting on the
be effectively particles.
classified owing However, increasing
to the higher drag
force
air acting
inlet on the
velocity overparticles. However,
the optimum increasing
value is able toair inlet velocity
decrease over the optimum
the classification precision value is able
because oftoa
decrease the classification precision because of a large difference in the velocity distribution in the
annular region [14]. This leads to air turbulence or collision of particles in the annular area.
It can be seen that under this air classification condition, there are no agglomerations of particles
observed in both products. However, it may be observed from Figure 11a that there are some small
particles mixed within the coarse product and also from Figure 11b that there are some large particles
mixed within the fine product. This might be the result of the fish-hook effect, which is the
phenomenon that the fine particles are collected and mixed into the coarse product, usually found
Processes 2019, 7, 427
in
12 of 16
particle size separation by hydrocyclone. The fish-hook effect is probably due to the feed material
consisting of particles with a wide range of particle size distribution [28]. In the turbo air classifier,
large
the difference
fish-hook in the
effect velocity
may distribution
be attributed in the
to the annular
increase inregion [14]. speed
rotational This leads
and to air powder
feed turbulence
withor
collisionsizes.
smaller of particles in theinannular
This results area.
a low efficiency of classification [27].

Figure 10.
Figure Particlesize
10. Particle sizedistributions
distributionsof
ofSAC305
SAC305powder
powderfrom
fromturbo
turboair
airclassifications
classifications performed
performed using
using
inlet air velocities of (a) 6.5 and (b) 8.5 m/s at the same rotor speed of 619 RPM and feed rate 4 kg/h.
inlet air velocities of (a) 6.5 and (b) 8.5 m/s at the same rotor speed of 619 RPM and feed rate 4 kg/h.

SEM micrographs of coarse and fine powder products from the turbo air classification using an
inlet air velocity of 8.5 m/s, rotor speed of 619 RPM, and feed rate of 4 kg/h, are shown in Figure 11.
It can be seen that under this air classification condition, there are no agglomerations of particles
observed in both products. However, it may be observed from Figure 11a that there are some small
particles mixed within the coarse product and also from Figure 11b that there are some large particles
mixed within the fine product. This might be the result of the fish-hook effect, which is the phenomenon
that the fine particles are collected and mixed into the coarse product, usually found in particle size
separation by hydrocyclone. The fish-hook effect is probably due to the feed material consisting of
particles with a wide range of particle size distribution [28]. In the turbo air classifier, the fish-hook
Processes 2019, 7, 427 13 of 16

effect may be attributed to the increase in rotational speed and feed powder with smaller sizes. This
results in a2019,
Processes low7,efficiency
x FOR PEERof classification [27].
REVIEW 13 of 16

Figure SEM
11.11.
Figure SEMmicrographs
micrographs of of
SAC305
SAC305lead-free solder
lead-free powder
solder powderproducts from
products turbo
from airair
turbo classification
classification
experiments using an air inlet velocity of 8.5 m/s, rotor speed 619 RPM, and feed rate 4 kg/h;
experiments using an air inlet velocity of 8.5 m/s, rotor speed 619 RPM, and feed rate 4 kg/h; (a) (a)
coarse
coarse
product and (b) fine product.
product and (b) fine product.

Figure 12 shows an elemental spectrum from EDS (Energy Dispersive Spectroscopy) analysis of
Figure 12 shows an elemental spectrum from EDS (Energy Dispersive Spectroscopy) analysis of
the SAC305 lead-free solder fine powder product. EDS (Oxford Instruments, High Wycombe, UK)
the SAC305 lead-free solder fine powder product. EDS (Oxford Instruments, High Wycombe, UK)
analysis was used to semi-quantitatively check the main chemical composition of the SAC powder
analysis was used to semi-quantitatively check the main chemical composition of the SAC powder
with regard to Sn, Ag, and Cu and also prohibited elements Pb and Cd which must not be contained in
with regard to Sn, Ag, and Cu and also prohibited elements Pb and Cd which must not be contained
a lead-free solder alloy. In the EDS analysis there were no elements subtracted from the analysis. The
in a lead-free solder alloy. In the EDS analysis there were no elements subtracted from the analysis.
composition of the fine powder product mainly consisted of Sn, Ag, and Cu. The elements Pb and
The composition of the fine powder product mainly consisted of Sn, Ag, and Cu. The elements Pb
Cd were not detected. It may be noted that peaks of C and O were also detected from the powder
and Cd were not detected. It may be noted that peaks of C and O were also detected from the powder
sample. The small amount of carbon present is possibly from the carbon adhesive tape, which is used
for adhering the powder sample onto the SEM specimen stub. The presence of oxygen is probably
from the oxide on the surface of powder itself. The surface of the powder can be easily oxidized and
form an oxide film is formed during powder production by the centrifugal atomization process [29].
Processes 2019, 7, 427 14 of 16

sample. The small amount of carbon present is possibly from the carbon adhesive tape, which is used
for adhering the powder sample onto the SEM specimen stub. The presence of oxygen is probably
from the oxide on the surface of powder itself. The surface of the powder can be easily oxidized
Processes 2019, 7, x FOR PEER REVIEW
and
14 of 16
form an oxide film is formed during powder production by the centrifugal atomization process [29].
It might
It might bebe oxidized
oxidized during
duringthe
theturbo
turboair
airclassification
classificationprocess
processasaswell
wellsince the
since process
the is performed
process is performed in
anan
in ambient
ambient airair
atmosphere.
atmosphere.

Figure 12. EDS

Figure 12. (Energy Dispersive
EDS (Energy Dispersive Spectroscopy)
Spectroscopy) spectrum
spectrum of
of SAC305
SAC305 lead-free
lead-free solder
solder fine powder
fine powder
product.
product.

4. Conclusions
Conclusions

In this work, the effects of operating parameters, namely, rotor speed, feed rate, the air inlet
velocity, of a turbo
turbo air classifier
classifier on its cut
cut size
size were
were studied
studied for particle
particle size separation of a SAC305
lead-free solder powder. The variations in rotor speed and air inlet velocity strongly affected the cut
size of classification, while the feed rate had a weaker effect. The The smallest
smallest cut
cut size
size of 27.8 μm
µm was
achieved when the turbo air classifier was operated at a rotor speed of 406 RPM, feed rate 4 kg/h, and
air inlet velocity 5 m/s. Even though an increase in rotor speed tended to reduce the cut size, particle
size separation did not completely take place at the too high rotor speed of 619 RPM. This limitation
might be attributed to the turbulence air flow in the separation zone (annular area) of the cage-type
separator. Rotor speed between 406 RPM and 619 RPM is an appropriate speed to operate the turbo
air classifier in order to obtain the target cut sizes sizes smaller
smaller than 27.8 µm. μm. The present work focused
only on cut size as a performance index of of the
the turbo
turbo air
air classifier;
classifier; however,
however, there are other indices for
evaluating the performance of powder classification, including the sharpness of classification and the
powder separation yield. These These two
two performance
performance indices
indices are are challenges
challenges and are recommended for
future study. It may be suggested that an appropriate design of the rotor cage is an important factor
affecting the
affecting the performance
performanceof ofthe
theturbo
turboair
airclassifier
classifiersince
sinceit itcan
cancreate a smooth
create a smooth velocity distribution
velocity of
distribution
airair
of flow in in
flow thethe
classifier. Hence,
classifier. Hence,thetheuse
useofofdifferent
differenttypes
typesofofrotor
rotorcage
cageininthe
the air
air turbo
turbo classifier for
future study on the size separation of high-density powders powders is is recommended.
recommended.

Author Contributions: N.D.,

Author Contributions: S.J. and
N.D. S.J. and K.B.
K.B. carried
carried out
out the
the experiment,
experiment, analyzed
analyzed the
the experimental results and
experimental results and
wrote the original draft. T.P. and S.J. analyzed the results and wrote the manuscript.
wrote the original draft. T.P. and S.J. analyzed the results and wrote the manuscript.
Funding: This research was funded by the Graduate School at Prince of Songkla University (PSU Ph.D. Scholarship
Funding:
grant) andThis researchGovernment
the Thailand was fundedResearch
by the Graduate School at Prince of Songkla University (PSU Ph.D.
grant ENG570120s.
Scholarship grant) and the Thailand Government Research grant ENG570120s.

Acknowledgments: The authors would like to thank the Department of Mining and Materials Engineering,
within the Faculty of Engineering, Prince of Songkla University, for their laboratory facilities. Moreover, the
authors are grateful for the PSU Ph.D. Scholarship grant of the Graduate School and the financial support
provided through the Thailand Government Research grant ENG570120s.

Conflicts of Interest: The authors declare no conflicts of interest.

Processes 2019, 7, 427 15 of 16

Acknowledgments: The authors would like to thank the Department of Mining and Materials Engineering, within
the Faculty of Engineering, Prince of Songkla University, for their laboratory facilities. Moreover, the authors are
grateful for the PSU Ph.D. Scholarship grant of the Graduate School and the financial support provided through
the Thailand Government Research grant ENG570120s.
Conflicts of Interest: The authors declare no conflicts of interest.

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