In intense pulsed light sintering (IPL), pulsed large-area visible light from a xenon lamp is absorbed by nanoparticle films or patterns and converted to heat, resulting in rapid sintering of the nanoparticles. This work experimentally characterizes IPL of silver nanoparticle films. A newly observed turning point in the evolution of film temperature during IPL is correlated to the observation, in literature and in this work, that film densification levels off beyond a critical pulse fluence and number of pulses. A computational model is developed that couples electromagnetic finite element analysis, heat transfer models and densification models to predict the evolution of film temperature and density during IPL. This model is able to capture the experimentally observed turning point in temperature during IPL, whereas current models of IPL are unable to do so. It is shown that the temperature turning point occurs due to a coupling between optical absorption and densification in the nanoparticle film, mediated by a change in nanoscale shape of the deposited nanoparticles due to interparticle neck growth. Further, it is found that the optical fluence per pulse has a greater effect on the achievable film density in IPL, as compared to the number of pulses.

Sintering of nanoparticle inks over large area-substrates is a key enabler for scalable fabrication of patterned and continuous films, with multiple emerging applications. The high speed and ambient condition operation of photonic sintering has elicited significant interest for this purpose. In this work, we experimentally characterize the temperature evolution and densification in photonic sintering of silver nanoparticle inks, as a function of nanoparticle size. It is shown that smaller nanoparticles result in faster densification, with lower temperatures during sintering, as compared to larger nanoparticles. Further, high densification can be achieved even without nanoparticle melting. Electromagnetic Finite Element Analysis of photonic heating is coupled to an analytical sintering model, to examine the role of interparticle neck growth in photonic sintering. It is shown that photonic sintering is an inherently self-damping process, i.e., the progress of densification reduces the magnitude of subsequent photonic heating even before full density is reached. By accounting for this phenomenon, the developed coupled model better captures the experimentally observed sintering temperature and densification as compared to conventional photonic sintering models. Further, this model is used to uncover the reason behind the experimentally observed increase in densification with increasing weight ratio of smaller to larger nanoparticles.

Intense pulsed light sintering of Ag nanoparticle–nanowire films shows reduced peak temperatures and a self-limiting behavior controlled by NW content.