Liquid Breakup Research Articles

Complete Breakup of Liquids into Ultrafine Droplets by Grid Turbulence.

Ultrafine droplets are crucial in materials processing and nanotechnology, with applications in nanoparticle preparation, water evaporation, nanodrug delivery, nanocoating, among numerous others. While the potential of turbulent gas flow to enhance liquid breakup is acknowledged, constructing turbulence-driven atomizers for ultrafine droplets remains challenging. Herein, we report the innovation of grid-turbulence atomization (GTA), which employs a rotating mesh to deliver liquid and an air knife to spray ultrafine droplets. The airflow across the mesh transitions from laminar flow to grid turbulence, resulting in complete liquid breakup through three stages: bag formation, stretching, and turbulence-induced breakup. Ultrafine water droplets with a 4.8 μm Sauter mean diameter were achieved through GTA. The GTA system demonstrates versatility in atomizing various liquids and proves effective for ultrafine spray-drying. Our strategic methodology establishes a pivotal link between turbulence characteristics and materials processing, influencing a wide range of applications and sparking further innovation in the field.

Experimental investigation on swirling annular liquid film breakup characteristics of prefilming airblast atomizer

In order to further improve the understanding of the liquid film breakup characteristics of prefilming airblast atomizer, the effects of key operating parameters and structural parameters (swirl intensity, diameter and number of injection holes on pilot stage, length of pre-film lip and sleeve angle) on the liquid film pattern of prefilming airblast atomizer were investigated using the high-speed shadow method and the Otsu’s method. The mechanism of liquid film breakage was analyzed, the results show that, with the increase of fuel injection pressure, the spray morphology experiences “columnar-shaped”, “tulip-shaped” and “fully cone-shaped”. Meanwhile, the main fluctuation frequency of liquid film varies from 100.5 Hz in the “columnar-shaped” and “tulip-shaped” to 25.12 Hz in the “fully cone-shaped”. With increasing relative pressure drops of swirler, the film breakup length and film fluctuation frequency decrease, while the film fluctuation amplitude increases. An increase in inner-stage swirl intensities will lead to a reduction in the film breakup distance, while an increase in outer-stage swirl intensities will mainly lead to a larger spray angle. The increase of the diameter and number of injection holes and the length of pre-film lip leads to the rise of the liquid film breakup length, while the decrease of sleeve angle mainly leads to the rise of spray angle, which makes the liquid film more easily broken.

Revealing mechanisms of processing defect mitigation in laser powder bed fusion via shaped beams using high-speed X-ray imaging

The laser powder bed fusion (LPBF) process utilizing a focused Gaussian-shaped beam faces challenges, including pore formation, melt pool fluctuation and liquid spattering. While beam shaping technology has been explored as a potential approach for defect mitigation, the beam-matter interaction dynamics during melting with shaped beams remain unclear. Here, we report the direct observation of ring-shaped beam-matter interaction dynamics, including pore formation, melt pool fluctuation and liquid spattering, and unveil defect mitigation mechanisms in ring-shaped beam laser powder bed fusion process. We find that, by spatially manipulating incident laser rays, the ring-shaped beam controls keyhole morphology, thereby managing the distribution of the reflected rays. This manipulation can effectively eliminate the formation of an unstable cavity at the keyhole tip, stabilizing the keyhole and mitigating keyhole pores. This enhanced keyhole stability effectively reduces the melt pool fluctuation, the formation of liquid breakup induced spatters and liquid droplet colliding induced large spatters in the laser powder bed fusion process. Additionally, the high-energy forefront of the ring-shaped beam effectively melts the powder bed, reducing agglomeration liquid spatter in the laser powder bed fusion process. The discovered defect mitigation mechanisms may guide the design of beam shaping strategies for simultaneously increasing the quality and productivity of metal additive manufacturing.

Computational study on the effect of thermodynamic operating conditions on primary atomization in pressure-swirl atomizers

Reducing pollutants and carbon emissions is a main and commonplace concern nowadays. Improving liquid breakup efficiency in injection processes for combustion applications may lead to important benefits in that regard. In this work, the effect of varying the injection conditions in terms of their thermodynamic state is studied when injecting liquid fuel into quiescent air through a simplex pressure-swirl atomizer. For that purpose, high-fidelity DNS-like simulations are carried out. Results, validated by comparing the spray macroscopic shape with experimental pictures, show a realistic breakup mechanism already observed in previous studies. An improvement in breakup capabilities is observed when preheating both fuel and air. In this case, the injected liquid sheet is thinner and presents more instabilities, leading to an earlier breakup in the axial direction. Besides, the generated droplet population is larger and finer than that of the ambient temperature injection, indicating a better atomization efficiency. A size-growing trend is observed in the droplet population for both cases when getting far away from the nozzle, but is more noticeable in the low-temperature condition. This investigation helps to understand the first stage of the liquid breakup in pressure-swirl atomizers. Its results, complemented with those from simulating different operating conditions or fuels for the same atomizer, can be used to elaborate prediction models able to faithfully represent the primary atomization outcomes when using lower resolution methods more accessible from the computational standpoint. Besides, the importance of internal injector flow characteristics is also demonstrated, particularly when considering liquid film thickness, both mean and fluctuation. These findings indicate that a possible model based on internal injector flow studies may also be feasible for determining atomization efficiency.

Study on aerodynamic breakup of non-Newtonian liquid droplets and the distribution characteristics of their sub-droplets

In industrial applications, the secondary breakup of droplets and the size distribution of their sub-droplets are crucial for atomization performance indicators. In this work, a high-speed digital camera is utilized to experimentally and theoretically study the secondary breakup process of xanthan gum (XG) droplets and the size distribution changes of resulting sub-droplets in continuous airflow by changing the Weber number and effective Ohnesorge number. In addition, a detailed study is conducted on the liquid ring with the highest liquid content. The results show that at low Weber numbers, the number of nodes generated at the XG droplet ring is the same as that of the water droplet, following “the combined R-T/aerodynamic drag” mechanism. However, the final diameter of the nodes differs significantly from that of the water droplet. The particle size of XG liquid ring nodes is not only affected by the Weber number but also decreases with the increase of the effective Ohnesorge number. The particle size of the remaining broken sub-droplets in the liquid ring decreases with the increase of the effective Ohnesorge number. Finally, the spatial range of droplet breakup under different parameters is described by using the liquid ring breakup angle, and it is found that the breakup angle of the liquid ring is mainly related to the breakup mode.

Detailed analysis on primary and secondary break up characteristics of liquid fuel jet in crossflow using homogeneous mixture model and large eddy simulation

The detailed breakup characteristics of the liquid jet fuel, Jet-A, in crossflow to various ranges of momentum flux ratios and Weber numbers have been investigated using a high-fidelity compressible multi-phase numerical technique. Multi-phase large eddy simulation with adaptive mesh refinement and Eulerian to Lagrangian transformation are applied to the homogeneous mixture model. The liquid surface instabilities and their frequencies inside the injector orifice are observed and analyzed. Interactions between liquid jet and crossflow result in phenomena such as horse-shoe vortex formation, boundary separation, liquid trailing, and counter-rotating vortex pair. Liquid column breakup characteristics and wave structures are analyzed from both temporal and spatial viewpoints. The Sauter mean diameter distribution and cumulative distributions of droplets resulting from secondary breakup are presented, along with the droplet size distribution derived from the momentum flux ratio and Weber number. Several engineering models, including the instability frequencies, the breakup length, and the penetration depth, are proposed in terms of the momentum flux ratio and Weber number, providing valuable insights for injector and combustor design.

Multi-scale flow atomization characteristics of Jatropha biodiesel swirl liquid film breakup

The characteristics of the spray and droplets produced by liquid film breakup are crucial for understanding the atomization process in industrial furnace atomizers. This study employed high-speed camera technology to capture images of Jatropha biodiesel (JB) spray at various pressures and Ohnesorge numbers (Oh). Image processing methods were employed to analyze the evolution morphology and proper orthogonal decomposition (POD) of fuel swirl spray, revealing the instability, breakup length, spray cone angle, fractal characteristics of the liquid film breakup zone, and droplet distribution characteristics. The results indicated that the JB jet evolution progressed through stages: cylindrical jet, torsion liquid film, open swirl, complete swirl, and fully developed mode. The evolution and disintegration of the liquid film exhibited a complex structure with ligaments, perforations, and droplet separation. Flow disturbances induced the Klystron effect, characterizing microscopic droplet motion. As spray pressure increased, the growth rate of the disturbance wave increased, the breakup length decreased, the atomization cone angle enlarged, and the fractal dimension (FD) of the liquid film breakup zone increased. The droplet size distribution followed a log-normal distribution, with a substantial increase in the number of small droplets as injection pressure increased. This study provides valuable insights into the multi-scale flow atomization of biodiesel in industrial furnace, and is of great significance for the design, operation, and optimization of spraying systems in various industrial applications.

Liquid breakup and droplets behavior of free triple-impinging jets with different impinging distance

The breakup characteristics and droplet behavior of free triple-impinging jets (FTIJs) were investigated using a high-speed camera. The liquid sheet and droplets breakup mechanism, liquid sheet breakup length, width, droplet diameter and velocity, were studied under different jet velocity and horizontal impinging distance and perpendicular impinging distance. The results revealed that with increasing jet velocity from 1.42 m/s to 6.61 m/s, different breakup modes were observed: closed-rim mode, open-rim mode, rimless mode, and wave or ligament mode. At low jet velocities, increasing impinging distance delayed the development of breakup mode. Based on experimental observations, the sheet breakup mechanism is categorized into two main regimes with four subregimes. Droplet breakup occurs in two stages: growth and necking, however, at high jet velocities complete breakup was achieved. Increasing jet velocity led to an increase in liquid sheet breakup length, width, and droplet velocity but a decrease in droplet diameter. Conversely, increasing impinging distance resulted in a decrease in liquid sheet breakup width and droplet radial velocity but an increase in droplet diameter. The effect of perpendicular impinging distance on axial velocity and breakup length was found to be more significant than that of horizontal impinging distance due to the effect of perpendicular nozzle. The findings indicate that the perpendicular jet greatly enhances atomization. This study provides a theoretical basis for designing and optimizing FTIJs.

Effects of Liquid Film Instability on Spray Features of Liquid–Liquid Pintle Injectors

As one of the crucial structural parameters for the pintle injectors, the design of the skip distance ratio is still heavily empirical-dependent in engineering, and the intrinsic correlations between the skip distance ratio and spray characteristics of liquid–liquid pintle injectors are also unclear. Inspired by the observations that the instability of axial liquid film exerts significant influence on the downstream spray behaviors of a liquid–liquid pintle injector, the influence of the skip distance ratio on the instability of the axial liquid film and the subsequent spray characteristics of the pintle injector was experimentally investigated. The spray steadiness of the pintle injector was evaluated based on the instantaneous images using the proper orthogonal decomposition technique, and the effects of the skip distance ratio and the momentum ratio on the spray features were analyzed. Furthermore, a proactive strategy was proposed to adjust the liquid film instability by modifying the outer wall morphology of the pintle post, and the verification experiments were carried out based on three different wall morphologies. It was discovered that the rough wall enhances the axial liquid film instability and promotes the liquid sheet breakup and atomization of the pintle injector. These results provide new insights and valuable references for the optimization design of pintle injectors.

Review on spray characteristics of liquid–liquid injectors in liquid rocket engines

Impinging-jet injectors, liquid–liquid coaxial swirl injectors, and liquid–liquid pintle injectors are representative liquid–liquid injectors in liquid rocket engines (LRE). For these liquid–liquid injectors, the atomization processes all involve the liquid impingement, including jet–jet, sheet–sheet, and jets/sheet–sheet impingement, respectively. After impingement, a liquid sheet forms and fragments. Based on these similarities, reviewing published literature on the spray characteristics of these three liquid–liquid injectors in LRE is necessary and will facilitate the investigation of spray characteristics of liquid–liquid pintle injectors to meet the progress of variable-thrust LRE. This review covers the following aspects of these injectors: basic spray morphology, liquid sheet characteristics and disintegration mechanisms, and atomization characteristics. For impinging-jet injectors, rim instability and impact wave play crucial roles in spray morphology and disintegration. Jet Weber number is of great importance for liquid sheet breakup length and mean droplet diameter. In the case of liquid–liquid coaxial swirl injectors, the overall spray morphology is similar to that of pressure swirl injectors, but it may feature two separate liquid sheets. The recess length strongly influences spray morphology, spray angle, breakup length, and Sauter mean diameter. Liquid–liquid pintle injectors can be simplified to injection element, in which the spray morphology resembles a cloak-like shape. In a complete pintle injector, the spray forms a conical liquid sheet. Momentum ratio proves to be the most significant parameter for predicting spray angle. Although the review indicates substantial progress has been made in understanding spray characteristics of liquid–liquid injectors, there remain several shortcomings that require further research, particularly for pintle injectors, which can be learned from the other two injectors.

Subgrid scale modeling of droplet bag breakup in VOF simulations

The mesh-dependency of the breakup of liquid films, including their breakup length scales and resulting drop size distributions, has long been an obstacle inhibiting the computational modeling of large-scale spray systems. With the aim of overcoming this barrier, this work presents a framework for the prediction and modeling of subgrid-thickness liquid film formation and breakup within two-phase simulations using the volume of fluid method. A two-plane interface reconstruction is used to capture the development of liquid films as their thickness decreases below the mesh size. The breakup of the film is predicted with a semi-analytical model that incorporates the film geometry captured through the two-plane reconstruction. The framework is validated against experiments of the bag breakup of a liquid drop at We=13.8 through the comparison of the resulting drop size and velocity distributions. The generated distributions show good agreement with experimental results for drop resolutions as low as 25.6 cells across the initial diameter. The presented framework enables these drop breakup simulations to be performed at a computational cost three orders of magnitude lower than the cost of simulations utilizing adaptive mesh refinement.

Instability and breakup of rayleigh-plateau jets with capillary wave induced by electrowetting-on-dielectric

This paper discusses the lateral disturbances of vertical liquid flow enhancement using electrowetting-on-dielectric (EWOD) technique, which effectively reducing the breakup length of the liquid flow and minimizing the formation of satellite droplets. The EWOD technology is characterized by its minimal space occupation and low energy consumption. The successful implementation of the EWOD phenomenon relies on the formation of a three-phase contact line (TPCL) between the electrodes and the liquid, and the novel EWOD tube structure design provides an extended TPCL, enhancing the amplitude of capillary waves. Through experimental and theoretical analysis, this paper identifies key parameters affecting the liquid breakup process, such as the gap depth, angle of the EWOD tube, EWOD voltage amplitude, and frequency of the AC electrical signal. The research results indicate that the proposed EWOD tube responds rapidly and can consistently and stably manage liquid breakup and reduce the number of satellite droplets.

Numerical study and experimental validation: A portioned calculation method for a large atomization field

Atomization and sprays are widely used in industry and agriculture. An appropriate atomization simulation method is essential in analyzing the liquid film-breaking process and atomization performance, especially in large-scale atomization field calculations. This study innovatively proposes a portioned method that combines existing fundamental atomization calculation models to balance computational accuracy and speed, finally achieving a full-scale numerical study of large atomization fields. This study employs the volume of fluid (VOF) model to measure the two-phase flow in the inner flow field and applies the discrete particle model (DPM) to analyze droplet behavior in the far-atomization field. In the near-atomization field, the VOF-to-DPM method connects the nozzle with the jet space, providing an effective numerical simulation of the liquid film formation and droplet breakup processes. Additionally, experiments on atomization using a pressure-swirl nozzle at different flow rates were conducted. Experimental data, such as atomization cone angle, flow distribution, and droplet particle size distribution, were obtained, and numerical calculations were performed using the large atomization field partitioned calculation model. The simulation results are utilized to explain the mechanisms of liquid film disintegration, while the experimental results are employed to validate the accuracy of the numerical model. The comparison revealed that the calculated results of the partitioned simulation approach align well with the experimental data. The maximum error in flow characteristics is 9.53%, in atomization cone angle is 6.16%, and in flow distribution is 3.67%, and there is a good agreement in particle size distribution with a maximum error of 17.58% in Sauter mean diameter, validating the accuracy of the portioned calculation method for large atomization fields.

Experimental investigation of liquid metal thread breakup in a cross junction

Experimental investigation of liquid metal thread breakup in a cross junction

Puffing/micro-explosion of two-liquid droplets: Effect of fuel shell composition

Theoretical research into the heat and mass transfer, hydrodynamic and physicochemical processes in combustion chambers of gas turbine engines usually implies that multi-component jet fuels are modeled using single-component liquids (saturated or cyclic hydrocarbons) and their substitutes. Due to an insoluble dispersed phase (e.g., water) in their composition, droplets consist of a noncombustible core and a liquid fuel shell. During heating, water droplets coalesce in fuel droplets to produce explosion-triggering volumes of liquid superheated to the boiling point. When heated, these heterogeneous droplets breakup in the micro-explosion and puffing modes. This study reports the numerical simulation results providing the temporal characteristics of heating and evaporation of heterogeneous droplets until puffing/micro-explosive breakup, when varying the composition of the fuel shell in the homologous series of saturated and cyclic (as illustrated by monocycloparaffins) hydrocarbons from C7 to C16. The conducted research has revealed that the variations in the breakup delay times in the homologous series of saturated and cyclic hydrocarbons are nonlinear. The breakup delay rates were found to increase substantially in the boundary points of the investigated series. Mechanisms to control droplet fragmentation delay time were identified for different initial and boundary conditions. A dimensionless complex reflecting the correlation between the critical conditions of composite liquid droplet breakup and the physicochemical properties of the fuel shell components was proposed.

Spray characteristics of different regions downstream of a swirl cup

The spray characteristics of different regions downstream of swirl cups play a critical role in cold start and re-ignition of gas turbines. The spray measurements were performed at the fuel pressures of 0.5, 0.8, 1.0, 1.5, and 2.0 MPa and the fuel temperatures of −23, −13, −3, 7, 17 and 27 ℃, respectively. The droplet size, droplet velocity, droplet number, and instantaneous spatial spray image of sprays from an aviation kerosene Jet-A were measured using a two-component phase Doppler particle analyzer and a digital off-axis holography system. As the fuel pressure and temperature increase, the Sauter Mean Diameter (SMD) and spray non-uniformity of the Spray Shear Layer (SSL) gradually decrease. As the fuel pressure increases, the SMD and spray non-uniformity of the Central Toroidal Recirculation Zone (CTRZ) gradually decrease, and the slopes of these curves both decrease. As the fuel pressure increases, the SMD and spray non-uniformity of the CTRZ rapidly decrease at the fuel temperature of −23 ℃, while slightly decrease at the fuel temperature of 27 ℃. The droplets in the CTRZ come from 3 different sources: simplex nozzle, venturi, and outside the CTRZ. As the fuel pressure increases, the proportion of droplets recirculated from outside the CTRZ decreases. This study proposed the concept of the “pressure critical point” for the swirl cups. As the fuel temperature decreases, the proportion of droplets recirculated from outside the CTRZ increases below the critical pressure, while decreases above the critical pressure. In addition, through the models of liquid film formation and breakup on the curved cylindrical wall, a semi-theoretical model was established to predict the SMD of SSL for swirl cups. The prediction uncertainty of this model is less than 6% for all 14 conditions in this paper.

Experimental Study on Atomization Characteristics of Swirl Nozzle under Annular Airflow Impingement

Pressure nozzles are widely used in spray drying and other industries. In order to improve the atomization characteristics of pressure cyclone nozzles, a new type of annular jet gas impingement atomization device is developed. We use high-speed imaging and digital image processing and other methods to analyze the spray characteristics of the different annular device configurations (using four, six, and eight tubes) and under different gas–liquid mass flow rates. It is shown that with an increase in the Air–Liquid mass Ratio (ALR), the liquid film breakup process changes from undulating sheet breakup to perforated sheet breakup and the breakup length decreases. The breakup length decreases the most under the condition of six-tube airflow with the range of 31–55%, while the Sauter mean diameter (SMD) basically does not change. With the increase in ALR and the Weber number of liquid (Wel), the droplet size distribution becomes more uniform. The spray characteristics of the atomizer assisted by gas jets reaches the best state when Wel = 4596.3 and m˙g = 1.97 g/s. The experimental conclusions have some guiding significance for the design and optimization of the atomization devices in spray drying towers.

The breakup and instability structures of liquid jets in subsonic crossflows

The breakup of water and Jet A fuel jets injected transverse into elevated temperature (up to 425 °C), combustion pre-heated, subsonic crossflows was investigated by internally fluorescing the liquid jet column. The fluorescent dye seeded test liquids were illuminated by a pulsed laser light that was transmitted within the injector using a quartz rod light-guide. High-resolution images isolating the intact liquid column from light scattered by the surrounding dense spray facilitated precise measurement of the liquid column breakup position and the size and distribution of windward column instability waves. The injector geometry consisted of a 1 mm circular orifice with an orifice length of 20 mm with a tapered inlet. Liquid jet to gaseous crossflow momentum flux ratios were varied from 6 to 266 and the gas Weber number was varied from 10.7 to 228. Empirical correlations were derived for the liquid column breakup coordinates and breakup time in addition to the average and local maximum instability wavelength and amplitude on the liquid column windward surface. The reported correlations provided key insight into atomization physics and aim to support the quantitative validation of high-fidelity numerical simulations of the liquid jet in subsonic crossflow.

Experimental study of liquid aluminum droplet breakup characteristics based on a Drop-on-demand (DOD) magnetohydrodynamic actuation

In magnetohydrodynamic (MHD) drop-on-demand (DOD) actuation, Lorentz force generated in different excitation stages are exerted on the liquid metal jet to form a "push-pull" mechanism, which is crucial for generating accurate and repeatable metal droplets. In this study, the important parameters of the excitation current waveform in the magnetohydrodynamic (MHD) process, including the influence of the excitation voltage pulse width ratio and current amplitude on the velocity, energy, volume, and breakup length of aluminum droplets are studied. The conversion process of surface energy and kinetic energy during the formation and fall stage of liquid droplets is analyzed. The results show that the negative and positive excitation voltage pulse width ratio of the MHD pump has a significant effect on the droplet velocity, breakup time, size, and sphericity. The amplitude of the excitation current and Hartmann number has a significant impact on the generation of stable droplets. The results show that the single droplet ejection state can be achieved within the Ha number between 319.5 and 391.1. As the Ha number increases, the volume, length, kinetic energy and surface energy of the droplets at breakup time also increase. The size of droplets can be adjusted by changing the amplitude of excitation waveform.

Surfactant-laden liquid thread breakup driven by thermal fluctuations

The breakup of liquid threads into droplets is crucial in various applications, such as nanoprinting, nanomanufacturing, and inkjet printing, where a detailed understanding of the thinning neck dynamics allows for a precise droplet control. Here, the role of surfactant in the breakup process is studied by many-body dissipative particle dynamics, in particular, the various regime transitions and thread profiles, shedding light on molecular-level intricacies of this process hitherto inaccessible to continuum theory and experiments. Moreover, the role of surfactant in the most unstable perturbation, the formed droplet size, and surfactant distributions have been unraveled. As surfactant concentration rises, both the wavelength and time to breakup steadily increase due to the lowering of surface tension below the critical micelle concentration (CMC) and viscous effects introduced by micelles above the CMC. These changes prior to the breakup lead to larger droplets being formed in cases with higher surfactant concentration. We also compared the thinning dynamics to existing theoretical predictions, revealing that the surfactant-laden breakup starts at the inertial regime and transitions into the thermal fluctuation regime when the concentration is increased. Thus, we illuminate the hitherto poorly investigated and intricate breakup process of surfactant-laden liquid threads driven by thermal fluctuations, contributing to a deeper understanding of this process at molecular scales.