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Intense Pulsed Light Sintering (IPL) uses pulsed, large-area, broad-spectrum visible light from a xenon lamp for rapid fusion of nanomaterials into films or patterns used in flexible sensors, solar cells, displays and other applications. Past work on the IPL of silver nanoparticles has shown that a self-damping coupling between densification and optical absorption governs the evolution of the deposited nanomaterial temperature during IPL. This work examines the influence of the nanomaterial shape distribution on this coupling and on the temperature evolution in IPL of silver nanowire–nanoparticle composite films. The film thickness, resistivity, micromorphology, crystallinity and optical properties are compared for varying ratios of nanowire to nanoparticle content in the film. It is shown for the first time, that increasing the nanowire content reduces the maximum film temperature during IPL from 240 °C to 150 °C and substantially alters the temperature evolution trends over consecutive pulses, while enabling film resistivity within 4–5 times that of bulk silver in 2.5 seconds of processing time. Nanoscale electromagnetic models are used to understand optical absorption as a function of changing ratio of nanowires to nanoparticles in a model assembly that emulates the IPL experiments performed here. The coupling between densification and optical absorption is found to inherently depend on the nanomaterial shape distribution and the ability of this phenomenon to explain the experimental temperature evolution trends is discussed. The implications of these observations for controlling self-damping coupling in IPL and the optimum nanoparticle to nanowire ratios for concurrently achieving high throughput, low processing temperatures, low material costs and low resistivity in IPL of conductive metallic nanomaterials are also described.

Controlling processing temperatures and self-limiting behaviour in intense pulsed sintering by tailoring nanomaterial shape distribution