A cost-effective, scalable and versatile method of preparing nano-ink without hazardous chemical precursors is a prerequisite for widespread adoption of printed electronics. Precursor-free synthesis by spark discharge is promising for this purpose. The synthesis of platinum nanoparticles (PtNPs) using a spark discharge under Ar, N₂, and air has been investigated to prepare highly conductive nano-ink. The size, chemical composition, and mass production rate of PtNPs significantly depended on the carrier gas. Pure metallic PtNPs with sizes of 5.5 ± 1.8 and 7.1 ± 2.4 nm were formed under Ar and N₂, respectively. PtNPs with sizes of 18.2 ± 9.0 nm produced using air consisted of amorphous oxide PtO and metallic Pt. The mass production rates of PtNPs were 53 ± 6, 366 ± 59, and 490 ± 36 mg/h using a spark discharge under Ar, N₂, and air, respectively. It was found that the energy dissipated in the spark gap is not a significant parameter that determines the mass production rate. Stable Pt nano-ink (25 wt.%) was prepared only on the basis of PtNPs synthesized under air. Narrow (about 30 μm) and conductive Pt lines were formed by the aerosol jet printing with prepared nano-ink. The resistivity of the Pt lines sintered at 750 °C was (1.2 ± 0.1)·10⁻⁷ Ω·m, which is about 1.1 times higher than that of bulk Pt.

This study investigates the processes of interaction of nanosecond pulsed-periodic laser radiation with the flow of aerosol agglomerates of gold nanoparticles synthesized in a spark discharge. Nanoparticles in a gas flow are spatially separated nano-objects whose interaction with each other and with the walls of an experimental cell was insignificant. Therefore, the energy absorbed by nanoparticles was used only for their own heating with further shape and size modification and on heat transfer to the surrounding gas. In the research, we used laser radiation with wavelengths of 527 and 1053 nm at pulse energies up to 900 µJ and pulse repetition rates up to 500 Hz. The dynamics of changes in the nanoparticles size during their sintering process depending on the laser pulses energy is characterized by an S-shaped shrinkage curve. Complete sintering of the initial agglomerates with their transformation into spherical nanoparticles is achieved by a series of impacting laser pulses. The result of nanoparticles’ laser modification is largely determined by the pulse energy and the efficiency of the nanoparticles’ radiation absorption.

An analyzed substance’s signal intensity and detection sensitivity in surface-enhanced Raman spectroscopy (SERS) significantly depend on the size and agglomeration degree of nanoparticles (NPs) forming the enhancing structure. Structures were manufactured by aerosol dry printing (ADP), where NPs’ agglomeration depends on printing conditions and additional particle modification techniques. The influence of agglomeration degree on SERS signal enhancement was studied in three types of printed structures using the methylene blue model molecule as an analyte. We demonstrated that the ratio between individual NPs and agglomerates in a studied structure strongly affects SERS signal amplification, and structures formed mainly from non-agglomerated NPs enhance the signal better. In this sense, aerosol NPs modified by pulsed laser radiation provide better results than thermally modified NPs, since in laser modification a larger number of individual NPs is observed due to the absence of secondary agglomeration effects in the gas stream. However, increasing gas flow may minimize the secondary agglomeration, since the time allotted for the agglomeration processes is reduced. In this paper, we show how different NPs’ agglomeration tendencies influence SERS enhancement to demonstrate the process of using ADP to form inexpensive and highly efficient SERS substrates with huge application potential.

In this paper, we investigated the interaction of nanosecond pulsed-periodic infrared (IR) laser radiation at a 50 and 500 Hz repetition rate with aerosol platinum (Pt) and silver (Ag) nanoparticles agglomerates obtained in a spark discharge. Results showed the complete transformation of Pt dendrite-like agglomerates with sizes of 300 nm into individual spherical nanoparticles directly in a gas flow under 1053 nm laser pulses with energy density 3.5 mJ/cm². Notably, the critical energy density required for this process depended on the size distribution and extinction of agglomerates nanoparticles. Based on the extinction cross-section spectra results, Ag nanoparticles exhibit a weaker extinction in the IR region in contrast to Pt, so they were not completely modified even under the pulses with energy density up to 12.7 mJ/cm². The obtained results for Ag and Pt laser sintering were compared with corresponding modification of gold (Au) nanoparticles studied in our previous work. Here we considered the sintering mechanisms for Ag, Pt and Au nanoparticles agglomerates in the aerosol phase and proposed the model of their laser sintering based on one-stage for Pt agglomerates and two-stage shrinkage processes for Au and Ag agglomerates.