Numerical study of hybrid binary Al2O3-Cu-H2O nanofluid coating boundary layer flow from an exponentially stretching/shrinking perforated substrate with Cattaneo-Christov heat flux, heat source, suction and multiple slip effects

Abstract

Modern coating systems are increasingly deploying nanomaterials which offer improved thermal performance. The optimization of these systems can benefit from more elegant fluid dynamic models of the coating process. Inspired by these advancements, the present investigation introduces a novel mathematical model to analyze the boundary layer transport in Al2O3-Cu-H2O hybrid binary nanofluid coating deposition on an exponentially stretching porous substrate (sheet). Lateral mass flux (suction) at the wall is also considered a heat source (generation) for hot spot manufacturing effects. To add further sophistication to the thermal conduction model, a non-Fourier approach is adopted which accurately incorporates thermal relaxation effects i.e. the Cattaneo-Christov heat flux (CCHF) model. The Tiwari-Das volume fraction nanoscale formulation is implemented for different combinations of Alumina (Al2O3) and Copper (Cu) metallic nanoparticles in an aqueous base fluid (H2O). Hydrodynamic wall and thermal slip are also included as they feature in coating processes. The fundamental equations governing mass, momentum, and energy conservation, along with the corresponding conditions at the wall (substrate) and free stream, are made dimensionless through suitable scaling similarity transformations. The resulting nonlinear coupled ordinary differential boundary value problem is subsequently addressed using the efficient MATLAB bvp4c routine. Special cases of the non-Fourier model are validated against published results, and the general model is further confirmed through validation using an Adams-Moulton 2-step predictor-corrector algorithm (AMPC). Furthermore, dual solutions of the generalized model are extracted and visualized. A comprehensive study of the effects of key thermophysical key parameters on momentum and thermal characteristics (velocity, temperature, skin friction and local Nusselt number) is conducted and solutions are visualized graphically. The computations show that higher temperatures are present with intensification in the thermal relaxation parameter (Cattaneo-Christov hyperbolic model parameter), which predicts therefore larger temperatures than the classical Parabolic heat conduction model using Fourier analysis. Effectively, thermal relaxation is responsible for finite heat wave propagation and produces more accurate estimations of heat transfer than the Fourier model. An increase in stretching parameter enhances the skin friction coefficient and elevates the local Nusselt number. As the thermal relaxation parameter increases, the temperature magnitudes corresponding to the first and second solutions are both enhanced as are thermal boundary layer thicknesses. An increase in wall suction induces an escalation in the first solution for velocity whereas it reduces the second solution velocity. Stronger wall suction suppresses temperatures. With increasing thermal slip, the boundary layer is cooled i.e. temperature plummets and thermal boundary layer thickness is decreased. Strong deceleration is induced with greater hydrodynamic (velocity) slip. Both first and second solutions for skin friction are elevated with shrinking whereas they are depressed with stretching. With greater velocity slip both the first and second solutions for skin friction are depleted with greater velocity slip for the shrinking case, whereas they are generally enhanced for the very strong stretching case. The computations offer some new insights into multi-physical thermal fluid dynamics of nanofluid-based coating systems.