Hey, just glad you're ok Terraphon - was a bit worried re blowtorch and all !
This is really interesting work. I guess we need to take care to heat the sample without the gasses and combustion products of the torch being able to react with the juice, so that we can rule out that as the reason for deposits forming and the 'bad smell' (btw, that's interesting news - that there is indeed that familiar 'scent' being generated). It is looking like slowing down the heating of the juice a little could really help. Exciting times
Something I thought I wrote about before, but can't see now, so here goes, is: People report that running the atomisers hotter, with a higher voltage, seems better for the atomiser as well as providing better vapor production. So how do we square this with our findings on deposit formation? Well, there can be a way to encompass both i think. On the face of it, running hotter should give more deposits, or does it? A higher heat would be expected to a) make burning more likely, but b) also make evaporation more likely. So, it seems that the evaporation 'benefits' more from the higher heat than the burning; hence, a little counter-intuitively, higher running temp/voltage could indeed be good for the atomiser (at least in terms of deposits; it could be worse for evaporation of the wire itself, but that should take a year to cause end-of-life, i would guess, whereas deposits cause a premature end-of-life).
It is a little complex because on the one hand speed of heating will be an important factor, and also max temperature. Then the relationship of VG viscosity with temperature. Hence I suspect the advantage of higher voltage/higher temp is through lowered viscosity of the VG - hence evaporation trumps burning (acts sooner). If all this conjecture is on the right lines, higher voltage plus slightly slower heat up could be the way forward to seeing longer lifetimes for our atomisers (and a vape with less traces of noxious gasses).
obscure footnote (if not a chemist, ignore this): it is just possible that Nickel in the atomiser coil is acting as a catalyst to degrade VG? Very unlikely scenario, but a (remote) possibility.
edit: logical inconsistency noticed: we cant go with both slower heating and higher max temp because that would mean passing the point of high burning ratio. So slowing the heating as a harm reduction strategy would be best used only with the cooler running standard 4v ish operating mode. With the higher voltage higher temp advantage, go with fast flash heating to bypass the burning phase as fast as possible would seem best.