Purpose In comparison to a nozzle with a larger/finite separation distance (Thanigaiarasu et al., 2019), a thin-lip nozzle (Srinivasarao et al., 2017) minimizes drag. Coaxial nozzles with thin lips are an appropriate tool for studying high subsonic jets because it does not create a dominant re-circulation zone. This study aims to analyze the characteristic of separation distances, between primary and secondary nozzles, within the range of 0.7–3.2 mm which can be considered a thin lip. Design/methodology/approach A separation distance of 0.7 (Papamoschou, 2004), 1.7 and 2.65 mm (Lovaraju and Rathakrishnan, 2011) is considered for the present study. The main nozzle exit Mach number is maintained at a subsonic condition of Mach 0.6, and the co-flowing nozzle exit Mach number is varied from 0% (secondary jet stopped/single jet) to 100% (Mach 0.6) in steps of 20% with respect to the main nozzle exit Mach number. A comparison was made between these velocity ratios for all three lip thicknesses in the present study. Design mesh and analysis were done by using Gambit 2.6.4 and Fluent 6.12. Velocity contours and turbulence contours were studied for qualitative analysis. Findings When lip thickness increases from 0.7 to 2.65 mm, the potential core length (PCL) of the primary jet decreases marginally. Additionally, the PCL of the primary jet elongates significantly as the velocity ratio increases. The primary shear layer is dominant at 20% co-flow (20 PCF), less dominant at 60% co-flow (60 PCF) and almost disappeared at 100% co-flow (100 PCF). Concurrently, the secondary shear layer almost disappeared in 20 PCF, dominant in 60 PCF and more dominant in 100 PCF. Different zones such as initial merging, intermediate and fully merged zones are quantitatively and qualitatively analyzed. Practical implications Co-flow nozzle is used in turbofan engine exhaust. The scaled-down model of a turbofan engine has been analyzed. Core length is directly proportional to the jet noise. The PCL signifies the jet noise reduction in a high-speed jet. For a low-velocity ratio, the potential core is reduced and hence can reduce the jet noise. At the same time, as the velocity ratio increases, the mass flow rate of the coaxial increases. The increase in the mass flow increases the thrust of the engine. The aircraft engine designer should analyze the requirement of the aircraft and choose the optimal velocity ratio coaxial nozzle for the engine exhaust (Papamoschou, 2004). Originality/value There have been many research studies carried out previously at various lip thickness such as 0.4 (Georgiadis, 2003), 0.7 (Papamoschou, 2004), 1.5 (Srinivasarao et al., 2014a), 1.7 (Sharma et al., 2008), 2 (Naren, Thanigaiarasu and Rathakrishnan, 2016), 2.65 (Lovaraju and Rathakrishnan, 2011), 3 (Inturiet al., 2022) and 3.2 mm (Perumal et al., 2020). However, there is no proper study to vary the lip thickness in this range from 0.7 to 3.2 mm to understand the flow behavior of a co-flowing jet.
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