Droplet Formation Time Research Articles

Numerical study on the effect of actuation parameters on the formation characteristics of metal droplets in magnetohydrodynamic drop-on-demand (DOD) jetting

Numerical simulations have investigated the effects of electromagnetic drive waveform amplitude and pulse width on the state of metal droplet generation during drop-on-demand printing of molten metal aluminum by electromagnetic drive. It indicates that positive and negative pulses of magnetohydrodynamic(MHD) actuation applied to the molten metal in the crucible can form a so-called “push-pull” effect, which is the main mechanism affecting droplet generation and breakup. The positive pressure pulse causes the liquid metal to be extruded outward, and the negative pressure pulse promotes the fluid retraction at the nozzle to promoting the thinning of the liquid bridge and the generation of liquid droplets. With the increase in the amplitude of the applied current, the ejected molten aluminum from the crucible experiences three states: no droplet, single droplet, and droplet with satellite droplets. In the single drop state, the droplet formation time is shortened as the current peak increases and the droplet volume increases with the increase of pulse width. The energy conversion and force changes during droplet formation and falling are analyzed. When the peak kinetic energy of the ejected molten metal exceeds its surface energy, the jet breaks up and generates a single droplet. For the actuation with constant amplitude and duration for positive pulses, extending the duration of negative pulses weakens the "pull" effect, leading to a transition from the generation of a single droplet to multiple droplets. The numerical simulation results provide information on the current amplitude, pulse width, and Weber number range necessary for stable single droplet generation.

Microfluidic droplet pinch-off modified by hard and soft colloids: A scaling transition

This Letter explores the influence of colloids at liquid-liquid interfaces on droplet pinch-off dynamics in microfluidic devices, examining hard polystyrene particles and soft pNIPAM microgels. We uncover a significant deviation in droplet formation time compared to pure systems, similarly to surfactant-laden systems, yet notably, colloids exert minimal impact on droplet size, indicating potential nonlinear effects. The dynamics of neck thinning without colloids agree with the classic pendant drop scaling laws, while particle presence replaces traditional viscous and inertial-viscous regimes with a single power law, suggesting an elastic behavior driven by soft particle interactions. Published by the American Physical Society 2024

3D printing in microfluidics: experimental optimization of droplet size and generation time through flow focusing, phase, and geometry variation.

Droplet-based microfluidics systems have become widely used in recent years thanks to their advantages, varying from the possibility of handling small fluid volumes to directly synthesizing and encapsulating various living forms for biological-related applications. The effectiveness of such systems mainly depends on the ability to control some of these systems' parameters, such as produced droplet size and formation time, which represents a challenging task. This work reports an experimental study on tuning droplet size and generation time in a flow-focusing geometry fabricated with stereolithography 3D printing by exploring the interplay of phase and geometrical parameters. We produced droplets at different low flow rates of continuous and dispersed phases to assess the effect of each of these phases on the droplets' size and formation time. We observed that smaller droplets were produced for high viscosity oil and water phase, along with high flow rates. In addition, changing the microfluidics channels' width, and morphology of the orifice has shown a similar effect on droplet size, as shown in the case of high-viscosity solutions. The variation of the bifurcation angle shows a noticeable variation in terms of the achieved droplet size and formation time. We further investigated the impact of modifying the width ratio of the continuous and dispersed phases on droplet formation.

Parameter control, characterization and stability of soy protein emulsion prepared by microfluidic technology.

A flow-focusing microfluidic device driven by pressure was employed in soy protein emulsions with uniform droplet size and good morphology. The results suggested that pressure was an essential factor for droplet formation. The optimum parameter was at a continuous phase pressure of 140mbar and dispersed phase pressure of 80mbar. Under this condition, the droplet formation time was shortened to 0.20s, with average sizes of 39-43μm and coefficient of variation of about 2%. Emulsion stability was improved with increasing soy protein isolate (SPI) concentrations. At SPI concentrations higher than 20mg/mL, the emulsions exhibited improved stability against changes in temperature, pH and salt concentration. Emulsions prepared in this manner exhibited superior oxidative stability than those prepared by conventional methods utilizing homogenizers. This study showed that microfluidic technology can be applied to soy protein emulsions as an effective tool for preparing droplets with uniform size and enhanced stability.

Experimental study on the dispersed phase droplet formation process in a circumferential shear flow in dripping regime

A simplified experimental device was designed to simulate the shear flow in a liquid-liquid cyclone reactor. And the dispersed phase droplet formation process in the shear flow in dripping regime was investigated. Four characteristic parameters, droplet growth time (Tg), shrink time (Ts), formation time (Tf) and size (d) were used to describe the formation process. All the parameters presented fluctuation with different serial droplet numbers. Therefore, the effect of dispersed phase inlet flow rate (vd) on the value and uniformity of the parameters are analyzed. The results indicate that with the increase of vd, Tg, Ts, Tf decrease firstly and then increase, while the droplet size gradually increases. Meanwhile, the uniformity of Tg decreases first and then basically tends to be stable, while that of Ts, Tf and d decreases firstly and then increases. Eventually, the optimal range of vd under different continuous phase inlet flow rate is provided.

Three-dimensional numerical analysis and experimental confirmation for investigating the ground-based lateral droplet ejection toward microgravity simulation

Rapid in situ manufacturing is significant in space exploration. Droplet-based printing technology with micrometer accuracy has great potential in space due to the advantages of convenient transportation, customized metal material, and good environmental adaptability. It could achieve the ground microgravity simulation by a small Bond number (Bo < 1). The present work proposes a new method to evaluate the reliability of the ground microgravity simulation in the lateral metallic droplet-based ejection. The three-dimensional model is developed to numerically analyze the droplet ejection dynamic process coupled with the volume of fluid method and the k–ω shear stress transport model. The model accuracy and efficiency are improved by the local fine grid. In addition, the computation is validated by the cryogenic alloy droplet ejection experiments and theoretical analysis. The proposed theoretical analysis equation has good agreement with the SnPb alloy droplet ejection trajectory. Reynolds number (Re), Weber number (We), Froude number (Fr), Ohnesorge number (Oh), and breakup length (Lb) are used to analyze the gravity influences on the droplet ejection process of different materials, nozzle length–diameter ratios, and crucible fluid unfilled heights. The ejection direction has little effect on the aluminum droplet formation time and breakup length and the gravity effect increases with the length–diameter ratio and unfilled heights. In simulated results, the minimum We number of the aluminum droplet formation is 0.22 and the cryogenic alloy droplet formation is 0.19. The reliability of ground physical microgravity simulation is dependent on material selection, and aluminum is more suitable than the cryogenic and SnPb alloys.

Studies of the Movement Mechanism of Droplets in Power-Law Fluids in a T-Junction Microchannel by the Lattice Boltzmann Method

The movement mechanisms of Newtonian droplets in power-law fluids in T-junction microchannels were studied with the lattice Boltzmann method. The effects of power-law index <i>n</i> , capillary number <i>C</i>_a, flow ratio <i>Q</i> , viscosity ratio <i>M</i>, and surface wettability <i>θ</i> on the droplet formation size, the formation time and the deformation index (<i>D</i>_I) were investigated in detail. The results show that, first, with the increase of power-law index n from 0.4 to 1.6, the droplet formation size decreases almost linearly, and both the droplet formation time and the deformation index decrease quickly at first and then much more slowly. Second, the influences of the viscosity ratio on the droplet formation size, the formation time and the deformation index are basically the same as those of the power law index. In addition, with the increases of <i>C</i>_a and <i>θ</i> of the main channel, the droplet formation size decreases almost linearly, while the droplet formation time and deformation index decrease rapidly at first and then slowly, and the decreasing rates weaken with the increase of the power-law index. At last, with the increase of flow ratio <i>Q</i> of the continuous phase over the dispersed phase, the droplet formation size increases, and the droplet formation time as well as the deformation index decrease.

The Importance of Interfacial Tension in Emulsification: Connecting Scaling Relations Used in Large Scale Preparation with Microfluidic Measurement Methods

This paper starts with short descriptions of emulsion preparation methods used at large and smaller scales. We give scaling relations as they are generally used, and focus on the central role that interfacial tension plays in these relations. The actual values of the interfacial tension are far from certain given the dynamic behavior of surface-active components, and the lack of measurement methods that can be applied to conditions as they occur during large-scale preparation. Microfluidic techniques are expected to be very instrumental in closing this gap. Reduction of interfacial tension resulting from emulsifier adsorption at the oil-water interface is a complex process that consists of various steps. We discuss them here, and present methods used to probe them. Specifically, methods based on microfluidic tools are of great interest to study short droplet formation times, and also coalescence behavior of droplets. We present the newest insights in this field, which are expected to bring interfacial tension observations to a level that is of direct relevance for the large-scale preparation of emulsions, and that of other multi-phase products.

Generation of an O/W emulsion in a flow-focusing microchip: Importance of wetting conditions and of dynamic interfacial tension

To date, there is no information on the microfluidic emulsification of dibutyl adipate and n-butyl acetate in water. Since these solvents are very suitable for microencapsulation by interfacial polymerization, it is highly necessary to study the emulsification behavior of these solvents in microchannels. This work shows that the microfluidic emulsification of these solvents in water may fail to obtain stabilised flow regimes. This is due to droplet coalescence and wall wetting, even if a hydrophilic microchip is used. Hydrodynamic results show that squeezing and dripping regimes are especially affected because of the wall wetting by the dispersed phase. This difficulty can be circumvented by adding a surfactant (here Tween 80) into the aqueous phase. However, high surfactant concentrations (ten times the critical micelle concentration) should be used for the water-dibutyl adipate system. Indeed, comparison of flow maps for several surfactant concentrations seems to indicate that the dynamic interfacial tension is higher than the one expected (equilibrium), for surfactant concentrations lower than one hundred times the critical micelle concentration. The estimated diffusion time of Tween 80 is compared to the droplet formation time at different conditions. The choice of more appropriate dimensionless numbers to represent flow maps is also discussed.

Inkjet jettability and physical characterization of water–ethanol solutions of low molecular weight sodium polyacrylate and poly-diallyl dimethyl ammonium chloride (polyDADMAC)

Polyelectrolytes are water-soluble polymers having repeat units carrying electrolyte groups. As polyionic molecules having like charge units, they are self-repelling with a rod-like conformation in solution. Inkjet applications of polyelectrolytes include particle dispersing, surface modification, and multilayer structures. This work investigates the physical properties of low molecular weight sodium polyacrylate (NaPA) and poly-diallyl dimethyl ammonium chloride (polyDADMAC) polyelectrolyte solutions in the water–ethanol mixture in relation to their behavior in inkjet deposition. In rotational rheometry measurements, the solutions are found to behave in a Newtonian fashion once the effects of experimental artifacts are taken into account. The range of NaPA concentrations that could be studied was limited to 1 wt./wt. % by the poor solubility of NaPA in the presence of ethanol, and at these concentrations, the addition of NaPA to the solvent did not have a significant effect on the jetting behavior. PolyDADMAC had good solubility, and concentrations up to 10 wt./wt. % were studied and jetted successfully. While an increase in polyelectrolyte concentration resulted in a slow increase in ink viscosity, this was not found to have a significant effect on the required jetting voltage or maximum stable jetting frequency, though drop detachment and satellite droplet formation times were found to increase. As a practical limitation of polyDADMAC inks, solvent evaporation was found to lead to idle nozzles becoming non-jetting, with the allowed idle time decreasing rapidly as ink polyDADMAC concentration increased. This non-jetting behavior is likely due to residence time at the nozzle exit leading to the local surface tension and/or viscosity increase, differing from the bulk ink properties.

Local analysis of Marangoni effects during and after droplet formation

AbstractThe influence on the mass transfer in liquid‐liquid extraction was investigated during droplet formation in a quiescent aqueous continuous phase for the two transition components, acetone and acetonitrile, in toluene. Both transition components have similar characteristics. However, an approximately eight times slower mass transfer of a droplet hanging on a capillary in relation to a rising droplet could be observed. The droplet formation time and the initial solute concentration are decisive for the mass transfer behaviour. A lower volumetric flow leads to slower droplet formation and a higher specific mass transfer area enhancing mass transfer, which is visualized via laser induced fluorescence (LIF). Additionally, as expected, higher initial solute concentrations promote Marangoni turbulences and thus mass transfer, which is measured via confocal Raman spectroscopy inside a fixed hanging droplet.

Field Test of Self-Cleaning Zr-Modified-TiO2-SiO2 Films on Glass with a Demonstration of Their Anti-Fogging Effect.

The number of commercial products claiming self-cleaning properties is rising and testing of long-term activity and durability of such coatings needs to be addressed more. The time-dependent changes of different characteristics like haze, transparency, and color are essential for transparent glazing materials. Herein, we aimed to examine whether the laboratory results obtained on the Zr-modified-titania-silica (TiZr) self-cleaning materials would translate to larger-scale outdoor-exposed testing. TiZr thin films were deposited via spraying onto float glass window surfaces and exposed into three different environments for 20 months. For comparison, a commercially available active SGG BIOCLEANTM glass and standard float glass were simultaneously exposed in the same conditions. It was shown that the self-cleaning property of either a commercial product or TiZr-coated float glass was not considerably effective in real field test conditions, although the previous laboratory tests showed pronounced photocatalytic activity of TiZr thin films. The inclination angle; however, was shown to have a considerable effect on the self-cleaning ability of samples, as did the rain patterns during the testing period. On the other hand, the anti-fogging effect of our TiZr material was very well expressed in controlled laboratory conditions (measuring droplet formation time) as well as in the real outdoor environment.

A Computational Model for the Analysis of Spreading of Viscoelastic Droplets over Flat Surfaces

The spreading of viscous and viscoelastic fluids on flat and curved surfaces is an important problem in many industrial and biomedical processes. In this work the spreading of a linear viscoelastic fluid with changing rheological properties over flat surfaces is investigated via a macroscopic model. The computational model is based on a macroscopic mathematical description of the gravitational, capillary, viscous, and elastic forces. The dynamics of droplet spreading are determined in sessile and pendant configurations for different droplet extrusion or formation times for a hyaluronic acid solution undergoing gelation. The computational model is employed to describe the spreading of hydrogel droplets for different extrusion times, droplet volumes, and surface/droplet configurations. The effect of extrusion time is shown to be significant in the rate and extent of spreading.

On the mechanism of deep craters formation under the action of high power ytterbium-fiber laser

Stability of a liquid crater wall formed under the action of an ytterbium-fiber laser in the course of the Nd3+:Y2O3 nanopowder production is studied theoretically. It has been shown that hydrodynamic instability can develop on the melt-vapor interface as a result of the tangential discontinuity of the velocity between the vapor stream and molten crater wall. The characteristic spatial and temporal scales are estimated in the framework of the proposed qualitative model, they are found to be 20-90 μm and 20-50 μs, respectively, that is in good agreement with experimental data. Thus, the droplet formation time (during which the amplitude of the boundary perturbation reaches the wavelength order) is much smaller than a pulse duration of the ytterbium-fiber laser (1360 μs). This means that a significant amount of material can be removed from the crater due to formation of microscale droplets during the irradiation. This mechanism can explain the much greater crater depth for the fiber laser than for CO2 laser (a pulse duration for which is 370 μs).

Dynamics of magnetic modulation of ferrofluid droplets for digital microfluidic applications

Active control of droplet generation in a microfluidic platform attracts interest for development of digital microfluidic devices ranging from biosensors to micro-reactors to point-of-care diagnostic devices. The present paper characterizes, through an unsteady three-dimensional Volume of Fluid (VOF) simulation, the active control of ferrofluid droplet generation in a microfluidic T-junction in presence of a non-uniform magnetic field created by an external magnetic dipole. Two distinctly different positions of the dipole were considered – one upstream of the junction and one downstream. While keeping the ferrofluid flow rate fixed, a parametric variation of the continuous phase capillary number, dipole strength, and dipole position was carried out. Differences in the flow behaviour in terms of dripping or jetting and the droplet characteristics in terms of droplet formation time period and droplet size were studied. The existence of a threshold dipole strength, below which the magnetic force was not able to influence the flow behaviour, was identified. It was also observed that, for dipoles placed upstream of the junction, droplet formation was suppressed at some higher dipole strengths, and this value was found to increase with increasing capillary number. Droplet time period was also found to increase with increasing dipole strength, along with droplet size, i.e. an increase in droplet volume.

Interfacial tension measured at high expansion rates and within milliseconds using microfluidics

To understand droplet formation and stabilisation, technologies are needed to measure interfacial tension at micrometer range and millisecond scale. In this paper, microtechnology is used, and that allows us to access these ranges and derive a model for surfactant free systems. The predicting power of the model was tested, and we found that it can be used to accurately (validated with >60 experiments) describe droplet size for a wide range of flow rates, interfacial tensions, and continuous phase viscosities.The model was used next to determine interfacial tensions in a system with hexadecane and sodium dodecylsulfate (SDS) solutions, and it was found that the model can be used for droplet formation times ranging from 0.4 to 9.4ms while using a wide range of process conditions.The method described here differs greatly from standard dynamic interfacial tension methods that use quiescent, mostly diffusion-limited situations. The effects that we measured are much faster due to enhanced mass transfer; this allows us to assess the typical time scales used in industrial emulsification devices.

Behavior of the plasma characteristic and droplet transfer in CO2 laser–GMAW-P hybrid welding

The plasma behavior and metal transfer in CO2 laser + GMAW-P hybrid welding have been investigated. A 650 nm laser, in conjunction with the shadow graph technique, is used to observe the metal transfer process. The effect of the mutual distance and laser power on the metal transfer has been discussed. The results indicate that the laser-induced plasma plume have a significant impact to the arc shape, resistance, electrode melting, droplet formation, detachment, and impingement onto the workpiece. The laser-induced plasma changes the conductive path and forces affecting on the droplet. High laser power and short distance between laser beam and arc (DLA) reduce the pulse base time (PB) of the voltage of phase, increase the droplet detachment time (PD) and the pulse current time (PP) of the voltage of phase, and it also lead to an upward and inward force near the bottom of the droplet. As a consequence, the droplet formation time is increased, and eventually an off-axis droplet phenomenon is deduced. The vapor jet force induced by the the keyhole plasma acts on the droplet as a retention force; this force decreases when the DLA becomes larger and increases when the laser power becomes higher. The observation may help in understanding the weld characteristics with respect to variation in mutual distance and laser power which may be beneficial in using the main process parameters to produce desired weld quality.

Liquid Phase Mass Transfer Coefficient of Carbon Dioxide Absorption by Water Droplet

A new experimental set-up was established to measure liquid phase mass transfer coefficient of CO2 absorption by single water droplet. The experiments were performed at 303.65 K and 323.15 K, with a droplet falling height of 0. 41 m and 0.59 m. The droplet formation time varies from 0.352 s to 2.315 s. The droplet diameter changes little and is around 2.5 mm. The effects of temperature, droplet falling height and droplet formation time on CO2 absorption by individual water droplet are discussed.

Jettable fluid space and jetting characteristics of a microprint head

AbstractThe influence of fluid droplet properties on the droplet-on-demand jetting of a Newtonian model fluid (water–isopropanol–ethylene glycol ternary system) has been studied. The composition of the fluid was adjusted to investigate how the Ohnesorge number ($\mathit{Oh}$) influences droplet formation (morphology and speed) by a microfabricated short-channel shear-mode piezoelectric transducer. The fluid space for satellite-free single droplet formation was indeed found to be bound by upper and lower $\mathit{Oh}$ limits, but these shift approximately linearly with the piezo pulse voltage amplitude ${V}_{o} $, which has a stronger influence on jetting characteristics than pulse length. Therefore the jettable fluid space can be depicted on a ${V}_{o} {{\ndash}}\mathit{Oh}$ diagram. Satellite-free droplets of the model fluid can be jetted over a wide $\mathit{Oh}$ range, at least 0.025 to 0.5 (corresponding to $Z= {\mathit{Oh}}^{\ensuremath{-} 1} $ of 40 to 2), by adjusting ${V}_{o} $ appropriately. Air drag was found to dominate droplet flight, as may be expected. This can be accurately modelled to yield droplet formation time, which turned out to be $20\text{{\ndash}} 30~\lrm{\ensuremath{\mu}} \mathrm{s} $ under a wide range of jetting conditions. The corresponding initial droplet speed was found to vary linearly with ${V}_{o} $, with a fluid-dependent threshold but a fluid-independent slope, and a minimum speed of about $2~\mathrm{m} ~{\mathrm{s} }^{\ensuremath{-} 1} $. This suggests the existence of iso-velocity lines that run substantially parallel to the lower jetting boundary in the ${V}_{o} {{\ndash}}\mathit{Oh}$ diagram.

Droplet charging regimes for ultrasonic atomization of a liquid electrolyte in an external electric field

Distinct regimes of droplet charging, determined by the dominant charge transport process, are identified for an ultrasonic droplet ejector using electrohydrodynamic computational simulations, a fundamental scale analysis, and experimental measurements. The regimes of droplet charging are determined by the relative magnitudes of the dimensionless Strouhal and electric Reynolds numbers, which are a function of the process (pressure forcing), advection, and charge relaxation time scales for charge transport. Optimal (net maximum) droplet charging has been identified to exist for conditions in which the electric Reynolds number is of the order of the inverse Strouhal number, i.e., the charge relaxation time is on the order of the pressure forcing (droplet formation) time scale. The conditions necessary for optimal droplet charging have been identified as a function of the dimensionless Debye number (i.e., liquid conductivity), external electric field (magnitude and duration), and atomization drive signal (frequency and amplitude). The specific regime of droplet charging also determines the functional relationship between droplet charge and charging electric field strength. The commonly expected linear relationship between droplet charge and external electric field strength is only found when either the inverse of the Strouhal number is less than the electric Reynolds number, i.e., the charge relaxation is slower than both the advection and external pressure forcing, or in the electrostatic limit, i.e., when charge relaxation is much faster than all other processes. The analysis provides a basic understanding of the dominant physics of droplet charging with implications to many important applications, such as electrospray mass spectrometry, ink jet printing, and drop-on-demand manufacturing.