A novel technique for producing metallic microjets and microdrops

A new technique for producing steady metallic jets is proposed. It allows the production of supercritical jets with Weber numbers well below unity, which entails important technological advantages over existing techniques. The metallic liquid is injected through a micrometer converging nozzle located inside a gas stream. Both the liquid jet and the coflowing gas current cross an orifice located in front of the nozzle. The gas stream stabilizes the jet by sweeping away the capillary waves growing on the free surface. In this way, one can steadily produce microjets with a kinetic energy much lower than the interfacial energy, a possibility that has been predicted theoretically (Gañán-Calvo in Phys Rev E 78:026304, 2008). Experiments were conducted with mercury to assess the performance of the new technique. The experimental results agreed remarkably well with the predictions calculated from the convective/absolute instability transition of the jet. The jet breakup mechanism did not correspond to classical Rayleigh instability, but to the growth of surface waves over a capillary column which ends at a fixed location. The results were compared with those obtained with the well-established flow focusing method to show that the new technique considerably favors the jet’s stability.     

Modelling compressible gas flow near the nozzle of a gas atomiser using a new unified model

In this paper, a unified numerical model is used to simulate the compressible gas flow, during the process of atomisation of liquid, near the atomiser nozzle in gas-only case studies. The flow of the under-expanded gas jets is studied, by analyzing the pressure field, density field and the spatial distribution of Mach number of the gas. The simulated predictions of gas status at the nozzle exit, the radial profile of Pitot pressure, aspiration pressure, and the spatial distribution of the density gradient, are compared with relevant experimental results and an analytical correlation, in order to validate and verify the application of this unified model in the numerical simulation of the gas dynamic behavior during gas atomisation. The simulation results show that the compressible gas flow near the nozzle of a discrete jet atomiser is different from that in a typical annular slit atomiser. Unlike existing models, this new formulation has the potential to be used in future to simulate the simultaneous flow of compressible gas and a weakly compressible liquid metal stream.     

Time-resolved dynamics of laser-induced micro-jets from thin liquid films

Laser-induced forward transfer (LIFT) is a high-resolution direct-write technique, which can print a wide range of liquid materials without a nozzle. In this process, a pulsed laser initiates the expulsion of a high-velocity micro-jet of fluid from a thin donor film. LIFT involves a novel regime for impulsively driven free-surface jetting in that viscous forces developed in the thin film become relevant within the jet lifetime. In this work, time-resolved microscopy is used to study the dynamics of the laser-induced ejection process. We consider the influence of thin metal and thick polymer laser-absorbing layers on the flow actuation mechanism and resulting jet dynamics. Both films exhibit a mechanism in which flow is driven by the rapid expansion of a gas bubble within the liquid film. We present high-resolution images of the transient gas cavities, the resulting ejection of high aspect ratio external jets, as well as the first images of re-entrant jets formed during LIFT. These observations are interpreted in the context of similar work on cavitation bubble formation near free surfaces and rigid interfaces. Additionally, by increasing the laser beam size used on the polymer absorbing layer, we observe a transition to an alternate mechanism for jet formation, which is driven by the rapid expansion of a blister on the polymer surface. We compare the dynamics of these blister-actuated jets to those of the gas-actuated mechanism. Finally, we analyze these results in the context of printing sensitive ink materials.     

A quantitative sub-grid air entrainment model for bubbly flows - plunging jets

The accurate prediction of air entrainment is critical in simulating various important multiphase (air/water) flows. In this paper, we present a sub-grid air entrainment model that quantitatively predicts the rate of air entrainment and subsequent disperse bubbly flow for a plunging jet. The derivation of this model is based on the two-stage (i.e., low and high liquid jet velocity) air entrainment mechanisms suggested by Sene [Sene KJ. Air entrainment by plunging jets. Chem Eng Sci 1988;43(10):2615-23]. This model was validated against extensive experimental data for water jets in air over a wide range of liquid velocities (from around 1 to 10 m/s) for the total rate of air entrainment. It was then implemented into an Eulerian/Eulerian two-fluid computational multiphase fluid dynamics (CMFD) model, wherein the liquid and the bubbles are modeled as two distinct continua. This multiphase model, supplemented by the new sub-grid air entrainment model, was used to predict the void fraction distribution underneath plunging water jets at different depths and water jet velocities. It was found that this approach yields results that match the experimental observations very well.     

Phenomena peculiar to underexpanded flows in supersonic micronozzles

In the present study, the characteristics of supersonic flows in micronozzles are experimentally and computationally investigated for Reynolds numbers ranging from 618 to 5560. In the experiments, the flows are created in a rectangular contoured nozzle whose heights at its throat and exit are 286 and 500 μm, respectively. The number-density distribution along the nozzle centerline is measured using the laser-induced fluorescence technique under an underexpanded condition for each Reynolds number. The experimental results reveal that the underexpanded flow expands along the streamwise direction in a range where the cross-sectional area of the nozzle is constant although the flow in such a range has been believed to be compressed owing to friction. The results also reveal that the unexpected range where the flow expands extends with a decrease in Reynolds number. In the computations, the Navier–Stokes equations are solved numerically. The computational results agree very well with the experimental results; i.e., the computational code used in the present study is validated by the experiments. By using the computational results, the reason for the appearance of the phenomena peculiar to supersonic micronozzle flows is discussed. As a result, it is found that information about the back pressure under which the flow is underexpanded can reach into the inside of a micronozzle. Such a property induces the unexpected phenomena observed in the experiments.     

CFD prediction of the trajectory of a liquid jet in a non-uniform air crossflow

This paper describes a predictive numerical modelling methodology for calculation of deflection and deformation of liquid jets in air crossflows. The methodology combines Jet Embedding (JE) with Volume-of-Fluid (VOF) in a computational fluid dynamics (CFD) based approach. The combined JE/VOF methodology applies the JE concept of modelling the air and liquid phases in separate but linked models, with a representation of the liquid column embedded in the crossflow model. The crossflow is modelled in a CFD calculation using CFX4.2 and the separate jet model is written in FORTRAN 77. A multi-fluid implementation of the VOF technique, in CFX4.2, is used to model deformation of the liquid column cross-section in a series of two-dimensional models along the column trajectory. The crossflow, jet and deformation calculations are linked by an iterative procedure which advances from the nozzle exit in a series of time-steps. The JE/VOF methodology is used to make a prediction of a time-average trajectory of a deflected liquid column, with a progressively deformed cross-section, in an air crossflow. The prediction demonstrates that the JE/VOF methodology is capable of producing a physically realistic result.     

Application of Compact Schemes to Large Eddy Simulation of Turbulent Jets

We present 3-D large eddy simulation (LES) results for a turbulent Mach 0.9 isothermal round jet at a Reynolds number of 100,000 (based on jet nozzle exit conditions and nozzle diameter). Our LES code is part of a Computational Aeroacoustics (CAA) methodology that couples surface integral acoustics techniques such as Kirchhoff's method and the Ffowcs Williams– Hawkings method with LES for the far field noise estimation of turbulent jets. The LES code employs high-order accurate compact differencing together with implicit spatial filtering and state-of-the-art non-reflecting boundary conditions. A localized dynamic Smagorinsky subgrid-scale (SGS) model is used for representing the effects of the unresolved scales on the resolved scales. A computational grid consisting of 12 million points was used in the present simulation. Mean flow results obtained in our simulation are found to be in very good agreement with the available experimental data of jets at similar flow conditions. Furthermore, the near field data provided by the LES is coupled with the Ffowcs Williams–Hawkings method to compute the far field noise. Far field aeroacoustics results are also presented and comparisons are made with experimental measurements of jets at similar flow conditions. The aeroacoustics results are encouraging and suggest further investigation of the effects of inflow conditions on the jet acoustic field.     

Large-eddy simulation in the near-field of a transient multi-component gas jet with density gradients

Large-eddy simulation (LES) is a research tool that is increasingly being used to study practical engineering flows because of continuous improvements in computational power. This paper outlines an LES model developed for the study of multi-component transient gas jets with density gradients. The compressible LES formulation together with the numerical model, boundary conditions, perturbation, and parallelization are discussed. A non-dissipative sixth-order finite difference scheme is used to discretize the governing equations, and a low-pass sixth-order spatial filtering scheme is employed to avoid the growth of high-frequency modes. The conditions at the boundaries are implemented using Navier–Stokes characteristic boundary conditions. In addition to code performance, results are presented from a study of an impulsively started jet at high pressure and temperature with an injected to ambient gas density ratio of approximately 3.5.     

Hydrodynamics of gas–liquid Taylor flow in rectangular microchannels

The effect of fluid properties and operating conditions on the generation of gas–liquid Taylor flow in microchannels has been investigated experimentally and numerically. Visualisation experiments and 2D numerical simulations have been performed to study bubble and slug lengths, liquid film hold-up and bubble velocities. The results show that the bubble and slug lengths increase as a function of the gas and liquid flow rate ratios. The bubble and slug lengths follow the model developed by Garstecki et?al. (Lab chip 6:437–446, 2006) and van Steijn et?al. (Chem Eng Sci 62:7505–7514, 2007), however, the model coefficients appear to be dependent on the liquid properties and flow conditions in some cases. The ratio of the bubble velocity to superficial two-phase velocity is close to unity, which confirms a thin liquid film under the assumption of a stagnant liquid film. Numerical simulations confirm the hypothesis of a stagnant liquid film and provide information on the thickness of the liquid film.     

Finite element solution of viscous jet flows with surface tension

A finite element method is used to study the effect of Reynolds number and surface tension on the expansion and contraction of jets of Newtonian liquids. For values of Reynolds numbers (based on tube diameter), below 14 the jets expand, and when Re > 14 the jets contract. For higher Reynolds numbers the jet diameter approaches a limiting value. It is also found that the surface tension has a considerable effect on low Reynolds number jet flows, becoming negligible at higher Reynolds numbers. As an example, if the surface tension parameter $\text{σ}\text{η}\text{u}$ is equal to unity, the creeping flow jet expansion is reduced by 4% relative to the case with no surface tension but when Re is equal to 20 and 50 the final jet diameters increase by only 0.2%. The calculated jet shapes are compared with available experimental results.     

Experimental and numerical modeling of the gas atomization nozzle for gas flow behavior

Gas atomization is a widely used process for manufacturing of fine metal- and alloy-powder. To ensure a stable process with high yields of metal powder, the negative pressure at the melt delivery tube tip base and no flow separation conditions are necessary for a good atomization process. An important feature of these jets is that flow separation may occur over the outer surface of the liquid delivery tube for some conditions. Flow separation cause solidification and accumulation of metal, leading to a shape alteration of the liquid delivery tube in gas atomization process. Using computational fluid dynamics (CFD) software, a parametric study was conducted to determine the effects of atomizing gas pressure on the melt delivery tube tip base pressure and flow separation. Atomization gas pressures of 1.0, 1.3, 1.7, 2.2, and 2.7 MPa were used in the CFD model to initialize the pressure in gas inlet. CFD simulations were performed and the modeling results were compared with experimental data. These results showed that the CFD modeling can be used for the estimation of the melt tip base pressure of the nozzle. It is found that the flow separation formation is strongly dependent on the atomizing gas pressure.     

Temporal analysis of power law liquid jets

In this paper we investigate the breakup mechanisms of power law liquid jets. The viscosity of the liquid is represented the Carreau-Yasuda model, and the surface tension of the liquid jet has a variation (gradient) along the jet axial direction. The surface tension gradient may be introduced by the thermal disturbance of the jet surface as it comes of out an orifice. The Carreau-Yasuda fluid has a power law viscosity bounded by two plateaus, the higher plateau at zero strain rate, μ₀, and the lower plateau at the infinite strain rate, μ_∞. The governing equation for the surface profile of the liquid jet is derived in the forms of a partial differential equation (PDE), as well as an ordinary differential equation (ODE). The PDE and ODE are solved for various cases of Carreau-Yasuda fluid to study the effect of fluid properties on jet breakup. The effects of various parameters on the instability behavior are studied in comparison with two Newtonian jets with upper and lower bound viscosities, μ₀ and μ_∞. A number of quantitative conclusions and sensitivities on the instability behavior of non-Newtonian jets are investigated. It is found that the jet breakup mechanism depends on the properties of the fluid as well as the wave number of the thermal disturbance that causes the surface tension gradient. In contrast to the Newtonian liquid where the jet surface profile has the same frequency as the surface tension gradient, the nonlinear nature of the Carreau-Yasuda constitutive behavior may enable the jet surface profile at frequencies higher than that of the surface tension gradient. This leads to significant surface profile oscillation within one wavelength of the surface tension gradient and the generation of small satellite drops. It is worth noting that at a small wave number the breakup time for the Carreau-Yasuda fluid maybe shorter than that of the Newtonian jet with μ_∞, although the Newtonian jet has a lower viscosity.     

Volume of liquid deposited per single event electrospraying controlled by nozzle front surface modification

Single event electrospraying (SEE) is a method for the on-demand deposition of picoliter volumes of liquid. To investigate the influence of the size of the meniscus on the volume deposited per SEE, glass capillaries were used with and without an anti-wetting coating comprising a self-assembled 1H,1H,2H,2H-perfluorodecyltrichlorosilane-based monolayer to control the meniscus size. The deposited volume was determined experimentally and we developed a model that incorporates electrostatics and electrodynamics on the one hand, and hydrostatics, fluid dynamics, and surface tension effects on the other hand. The volumes deposited from both a capillary with unmodified nozzle front (large meniscus) and from a capillary with a modified nozzle front (small meniscus) can be predicted by the theoretical model.     

Fast geometry scaling of miniaturized microwave couplers with power split correction

Redesigning a microwave circuit for various operating conditions is a practically important yet challenging problem. The purpose of this article is development and presentation of a technique for fast geometry scaling of miniaturized microwave couplers with respect to operating frequency. Our approach exploits an inverse surrogate model constructed using several reference designs that are optimized for a set of operating frequencies within a range of interest. For the sake of computational efficiency, the reference designs are obtained for an equivalent network model of the coupler. The surrogate directly predicts the optimum values of geometry parameters of the structure at hand corresponding to a requested operating frequency. By introducing appropriate correction, the model allows for coupler scaling at the EM simulation model level. Because the surrogate does not carry information about the power split ratio of the coupler, an additional analytical corrective procedure is developed to ensure an equal power split of scaled structure. The computational cost of the scaling procedure corresponds to only two EM analyses of the circuit at hand (including both correction steps). The operation and performance of our technique is demonstrated using a compact microstrip rat‐race coupler scaled for the operating frequency range of 0.5‐2.5 GHz. Experimental validation is also provided.     

双锥流量计的气水两相流流量测量研究

采用一种新型双锥流量计,对气水两相流流量的测量进行试验研究。通过试验的方法,在水流量标准装置上对双锥流量计的流出系数进行了标定。利用双锥流量计的差压信号,采用分相流模型、Lin模型和Murdock模型对气水两相流的总流量测量进行了初步的研究。结果表明,在一定的测量范围内,采用Murdock模型可以获得较好的测量结果。     

Improving jet reactor configuration for production of carbon nanotubes

The jet mixing reactor has been proposed for the industrial production of fullerence carbon nanotubes. The goal is to obtain a uniformly high temperature of a catalyst. The mixing flowfield is studied using the semi-implicit method for pressure-linked equations revised algorithm. Hot peripheral jets are used to enhance heating of the central jet by mixing with the ambience of the reactor. Numerous configurations of peripheral jets with various numbers of jets, distance between nozzles, angles between the central jet and a peripheral jet, and twisted configuration of nozzles are considered. Unlike the previous studies of jet mixing, the optimal configuration of peripheral jets produces strong stretching of a cross-section of the central jet that enhances the mixing of the central jet with the reactor ambience.     

Quasi-acoustic scheme for gas dynamics Euler equations in the two-dimensional case

The new algorithm for numerically solving the gas dynamic Euler equations is presented. The algorithm is based on the linear reconstruction and quasi-acoustic presentation solution within a computational mesh. The proposed method is adapted for the three-dimensional (3D) case. Application problem is solved on the interaction of gas jets emitted from an aircraft engine interact with a reflecting screen.     

A neuro-genetic approach for selection of process parameters in abrasive waterjet cutting considering variation in diameter of focusing nozzle

This paper presents a neuro-genetic approach proposed to suggest the process parameters for maintaining the desired depth of cut in abrasive waterjet (AWJ) cutting by considering the change in diameter of focusing nozzle, i.e. for adaptive control of AWJ cutting process. An artificial neural network (ANN) based model is developed for prediction of depth of cut by considering the diameter of focusing nozzle along with the controllable process parameters such as water pressure, abrasive flow rate, jet traverse rate. ANN model combined with genetic algorithm (GA), i.e. neuro-genetic approach, is proposed to suggest the process parameters. Further, the merits of the proposed approach is shown by comparing the results obtained with the proposed approach to the results obtained with fuzzy-genetic approach [P.S. Chakravarthy, N. Ramesh Babu, A hybrid approach for selection of optimal process parameters in abrasive water jet cutting, Proceedings of the Institution of Mechanical Engineers, Part B: J. Eng. Manuf. 214 (2000) 781–791]. Finally, the effectiveness of the proposed approach is assessed by conducting the experiments with the suggested process parameters and comparing them with the desired results.     

固体火箭发动机喷管两相流场与结构温度场一体化数值模拟与软件实现

为准确、高效地进行固体火箭发动机的喷管结构设计与性能分析,考虑两相流场和结构温度场之间的相互影响,采用有限差分方法求解二维轴对称两相欧拉方程组,进行喷管气体-颗粒两相无黏流动数值模拟;采用有限元法求解二维轴对称瞬态导热微分方程,进行喷管复合结构温度场数值模拟;根据面向对象编程思想,采用VC+ +以人机交互的工作方式实现喷管内型面和结构设计,并完成有限差分网格和有限元网格的自动划分和显示;通过数值模拟方法与面向对象软件设计方法的有效结合,实现二维轴对称喷管两相无黏流场和复合结构温度场的一体化数值模拟. 数值模拟结果表明,该方法有助于在统一的软件平台上充分利用计算机辅助技术完成喷管性能与结构的综合评估,可以用于固体火箭发动机喷管的工程设计.     

Numerical computation of momentum jets and forced plums

A numerical study of vertical momentum jets and forced plumes issuing to similar receiving media is presented. The complete partial differential equations governing steady, incompressible, turbulent flow are solved in axisymmetric coordinates using finite-difference techniques. Solutions were based on the stream function-vorticity transport approach for a Boussinesq fluid. Buoyant driving forces were coupled to the vorticity equation by a buoyancy transport equation wich included effects of temperature and other constituents. Turbulent transport coefficients were computed iteratively using the Prandt eddy diffusivitiy model. Results for the momentum jet, axial and radial distributions of velocity and concentration, show excellent agreement with published data. Forced plum computations are presented which include similar results for densimetric Froude numbers ranging from 1 to 1000.