Macroscopic analysis of gas-jet wiping: Numerical simulation and experimental approach

Abstract

Coating techniques are frequently used in industrial processes such as paper manufacturing, wire sleeving, and in the iron and steel industry. Depending on the application considered, the thickness of the resulting substrate is controlled by mechanical (scraper), electromagnetic (if the entrained fluid is appropriated), or hydrodynamic (gas-jet wiping) operations. This paper deals with the latter process, referred to as gas-jet wiping, in which a turbulent slot jet is used to wipe the coating film dragged by a moving substrate. This mechanism relies on the gas-jet–liquid film interaction taking place on the moving surface. The aim of this study is to compare the results obtained by a lubrication one–dimensional model, numerical volume of fluid–large eddy simulation (VOF-LES) modeling and an experimental approach. The investigation emphasizes the effect of the controlling wiping parameters, i.e., the pressure gradient and shear stress distributions induced by the jet, on the shape of the liquid film. Those profiles obtained experimentally and numerically for a jet impinging on a dry fixed surface are compared. The effect of the substrate motion and the presence of the dragged liquid film on these actuators are analyzed through numerical simulations. Good agreement is found between the film thickness profile in the wiping zone obtained from the VOF-LES simulations and with the analytical model, provided that a good model for the wiping actuators is used. The effect of the gas-jet nozzle to substrate standoff distance on the final coating thickness is analyzed; the experimental and predicted values are compared for a wide set of conditions. Finally, the occurrence of the splashing phenomenon, which is characterized by the ejection of droplets from the runback film flow at jet impingement, thus limiting the wiping process, is investigated through experiments and numerical simulations.