Droplet Generation Process Research Articles

A soft microchannel decreases polydispersity of droplet generation.

We study the effect of softness of the microchannel on the process of droplet generation in two-phase flows in a T-junction microchannel. One side of the microchannel has a flexible thin PDMS layer, which vibrates naturally while droplets are generated; the deformation frequency coincides with the frequency of droplet formation. Furthermore, we compare the polydispersity of water-in-oil droplets formed with a microchannel with one soft wall with those formed in a conventional rigid microchannel. We show that deformation of the soft wall reduces the polydispersity in the droplet size.

Laser Droplet Generation from a Metal Foil

Abstract Metal droplets are used in various droplet based innovative technologies, especially in joining of temperature sensitive components where the amount of applied energy and its spatial distribution are important. Laser light has already been proved to be a suitable energy source for metal droplet generation, since it enables high spatial and temporal control of the energy input. In this contribution, a novel process of laser droplet generation (LDG) from a metal foil is presented, which could provide increased flexibility of the generated droplet parameters compared to the existing LDG processes. In the novel LDGprocess, a horizontally placed foil is irradiated by a laser beam from above and the melted part of the foil is detached by shielding gas overpressure above the foil. The results of presented preliminary experimental study show that droplet formation from metal foil is possible by means of an annular laser beam. In addition to this, the space of process parameters is explored,showing influences of temporal intensity distributions of the annular laser beam, shielding gas overpressure, and foil thickness and material on the process outcome.

Splashing in Oxygen Steelmaking

In oxygen steelmaking, splashing from the injection of oxygen plays an important role in the kinetics of the process. Though waves inside the cavity and formation of various modes (i.e. dimpling, splashing, and penetrating) have been investigated in the past, it is not clearly understood how these wave behaviour affects splashing. Therefore, in the present work, a cold model experimental study has been carried to establish if it was possible to quantitatively identify various modes of cavity. Fast Fourier Transform (FFT) on cavity depth oscillation showed that amplitude and frequency of cavity oscillation is highest in penetrating mode. Important aspects of the droplet generation process were identified from high speed imaging. Formation of sheet structure was identified and the height of these structures above the bath surface were found to decline as the cavity mode changed from splashing to penetrating. Existence of the splash sheets emphasizes that the sampling position can be a crucial issue in interpreting plant studies.

Effect of operation conditions of the drop-on-demand aerosol generator on aerosol characteristics: Pseudo-cinematographic and plasma mass spectrometric studies

The recently presented drop-on-demand (DOD) aerosol generator overcomes some of the drawbacks of pneumatic nebulization, as its aerosol is no longer generated by gas–liquid interaction. In the current study, an advanced imaging technique is presented, based on a CCD camera equipped with magnifying telecentric optics to allow for fast, automated and precise aerosol characterization as well as fundamental studies on the droplet generation processes by means of pseudo-cinematography.The DOD aerosol generator is thoroughly characterized regarding its droplet size distribution, which shows few distinct populations rather than a continuous distribution. Other important figures, such as the Sauter diameter (D3,2) of 22μm and the span of 0.4 were also determined. Additionally, the influence of the electrical operation conditions of the dosing device on the aerosol generation process is described. The number and volume of the generated droplets were found to be very reproducible and user-variable, e.g. from 17 to 27μm (D3,2), within a span of 0.07–0.89. The performances of different setups of the DOD as liquid sample introduction system in ICP-MS are correlated to the respective achievable aerosol characteristics and are also compared to the performance of a state-of-the-art μ-flow nebulizer (EnyaMist). The DOD system allowed for improved sensitivity, but slightly elevated signal noise and overall comparable limits of detection. The results are critically discussed and future directions are outlined.

INSTANTANEOUS FREQUENCY-BASED ANALYSIS AND CHARACTERIZATION OF LASER GENERATED DROPLET SEQUENCE DYNAMICS

In the laser droplet generation process three different dripping regimes are experimentally observed in dependence on the detachment pulse power. Besides being nonlinear, the process is also inherently nonstationary. In order to consistently analyze all the dripping scenarios based on an experimental time series, time-frequency analysis by means of instantaneous frequency is used. For the calculation of instantaneous frequency, the most recent developments of the Hilbert–Huang transform are applied, i.e. ensemble empirical mode decomposition, empirical amplitude/frequency modulation decomposition, and direct quadrature. In time-frequency spectra specific patterns are associated with corresponding dripping regimes. By means of a detailed inspection of patterns, the influence of the detachment pulse power on dripping dynamics is characterized.

MHD printhead for additive manufacturing of metals

Within the scope of additive manufacturing of metal parts, a droplet generator for metal melts is proposed. Its magnetohydrodynamic (MHD) working principle is shown and the actuation force available for droplet generation is calculated. The design of such a printhead is shown to consist only of very few, non-moving parts and therefore it is of great simplicity. First results gained with a prototype printhead show that successful droplet generation is possible, but that pollution of the melt with oxides and sparks developing during the droplet generation process have to be overcome to fully exploit the potential of the proposed print head.

Fluorescence detection methods for microfluidic droplet platforms

The development of microfluidic platforms for performing chemistry and biology has in large part been driven by a range of potential benefits that accompany system miniaturisation. Advantages include the ability to efficiently process nano- to femoto- liter volumes of sample, facile integration of functional components, an intrinsic predisposition towards large-scale multiplexing, enhanced analytical throughput, improved control and reduced instrumental footprints.1 In recent years much interest has focussed on the development of droplet-based (or segmented flow) microfluidic systems and their potential as platforms in high-throughput experimentation.2-4 Here water-in-oil emulsions are made to spontaneously form in microfluidic channels as a result of capillary instabilities between the two immiscible phases. Importantly, microdroplets of precisely defined volumes and compositions can be generated at frequencies of several kHz. Furthermore, by encapsulating reagents of interest within isolated compartments separated by a continuous immiscible phase, both sample cross-talk and dispersion (diffusion- and Taylor-based) can be eliminated, which leads to minimal cross-contamination and the ability to time analytical processes with great accuracy. Additionally, since there is no contact between the contents of the droplets and the channel walls (which are wetted by the continuous phase) absorption and loss of reagents on the channel walls is prevented. Once droplets of this kind have been generated and processed, it is necessary to extract the required analytical information. In this respect the detection method of choice should be rapid, provide high-sensitivity and low limits of detection, be applicable to a range of molecular species, be non-destructive and be able to be integrated with microfluidic devices in a facile manner. To address this need we have developed a suite of experimental tools and protocols that enable the extraction of large amounts of photophysical information from small-volume environments, and are applicable to the analysis of a wide range of physical, chemical and biological parameters. Herein two examples of these methods are presented and applied to the detection of single cells and the mapping of mixing processes inside picoliter-volume droplets. We report the entire experimental process including microfluidic chip fabrication, the optical setup and the process of droplet generation and detection.

Fluorescence detection methods for microfluidic droplet platforms

The development of microfluidic platforms for performing chemistry and biology has in large part been driven by a range of potential benefits that accompany system miniaturisation. Advantages include the ability to efficiently process nano- to femoto- liter volumes of sample, facile integration of functional components, an intrinsic predisposition towards large-scale multiplexing, enhanced analytical throughput, improved control and reduced instrumental footprints.1In recent years much interest has focussed on the development of droplet-based (or segmented flow) microfluidic systems and their potential as platforms in high-throughput experimentation.2-4 Here water-in-oil emulsions are made to spontaneously form in microfluidic channels as a result of capillary instabilities between the two immiscible phases. Importantly, microdroplets of precisely defined volumes and compositions can be generated at frequencies of several kHz. Furthermore, by encapsulating reagents of interest within isolated compartments separated by a continuous immiscible phase, both sample cross-talk and dispersion (diffusion- and Taylor-based) can be eliminated, which leads to minimal cross-contamination and the ability to time analytical processes with great accuracy. Additionally, since there is no contact between the contents of the droplets and the channel walls (which are wetted by the continuous phase) absorption and loss of reagents on the channel walls is prevented.Once droplets of this kind have been generated and processed, it is necessary to extract the required analytical information. In this respect the detection method of choice should be rapid, provide high-sensitivity and low limits of detection, be applicable to a range of molecular species, be non-destructive and be able to be integrated with microfluidic devices in a facile manner. To address this need we have developed a suite of experimental tools and protocols that enable the extraction of large amounts of photophysical information from small-volume environments, and are applicable to the analysis of a wide range of physical, chemical and biological parameters. Herein two examples of these methods are presented and applied to the detection of single cells and the mapping of mixing processes inside picoliter-volume droplets. We report the entire experimental process including microfluidic chip fabrication, the optical setup and the process of droplet generation and detection.

Numerical Simulation of Micro Flow Field of Micro Injector

In order to research the effects of digital micro droplet injected by the piezoelectric ceramic inertial driver, the calculation model of micro flow field of micro injector was established based on the VOF model of multiphase flow. The calculation selected the implicit segregated solver and the standard k-e model was used in turbulence of the micro-nozzle. The governing equation was separated in first order upwind, and solved by PISO algorithm. The flow pattern of the micro channel fluid and the dynamic evolution process of the micro droplet generation in the plus wave driving were researched.

CFD analysis of microchannel emulsification: Droplet generation process and size effect of asymmetric straight flow-through microchannels

Asymmetric straight flow-through microchannel (MC) arrays are high-performance MC emulsification devices for stable mass production of uniform droplets. This paper presents computational fluid dynamics (CFD) simulation and analysis of the generation of soybean oil-in-water emulsion droplets via asymmetric straight flow-through MCs, each consisting of a microslot and a narrow MC. We also used CFD to investigate the effects of the channel size and the flow of the dispersed phase on MC emulsification using asymmetric straight flow-through MCs with a characteristic channel size of 5–400 μm. The overall shape of an oil–water interface and the time scale during droplet generation via a control asymmetric straight flow-through MC were appropriately simulated. Better insight was obtained on the flow profile of the two phases and the internal pressure balance of the dispersed phase during droplet generation. Comparison of the CFD and experiment results also provided insight into dynamic interfacial tension during droplet generation. Successful droplet generation was observed below a critical dispersed-phase velocity. In this case, the resultant droplet size was proportional to the channel size and was not sensitive to the dispersed-phase velocity applied. The maximum droplet generation rate per channel was inversely proportional to the channel size, unless the buoyancy force did not promote droplet detachment. The maximum droplet productivity per unit area of an asymmetric straight flow-through MC array was estimated to be constant, regardless of channel size.

Nonlinear analysis of laser droplet generation by means of 0–1 test for chaos

We apply the recently improved version of the 0–1 test for chaos to real experimental time series of laser droplet generation process. In particular two marginal regimes of dripping are considered: spontaneous and forced dripping. The outcomes of the test reveal that both spontaneous and forced dripping time series can be characterized as chaotic, which coincides with the previous analysis based on nonlinear time series analysis.

Recurrence quantification analysis of intermittent spontaneous to forced dripping transition in laser droplet generation

In laser droplet generation a laser pulse, composed of primary and detachment part, is used to form and detach a pendant droplet from the end of a metal wire. We analyze the dynamics of laser droplet generation process in dependence on the detachment pulse power. Dynamically three different dripping regimes have been observed: spontaneous, forced and intermittent dripping regime. We characterize these behaviors by means of recurrence plots and their quantification and argue that dynamics is getting more irregular with increasing the detachment pulse power, resembling an intermittent chaos-to-chaos transition.

Detailed Numerical Simulation toward Understanding the Liquid Spray Formation Mechanisms

Detailed numerical simulations of Diesel liquid jet sprays have been conducted to elucidate the liquid atomization mechanisms. The obtained flow field is very complicated, but the spray behavior can be understood physically. The jet head formation leads to vortex shedding and subsequent atomization from the head edge. The liquid core surface is also unstable due to gas boundary layer instability and atomization also occurs from here. The final process of droplet generation from a ligament is basically the same as the past research results, and can be explained by the capillary wave destabilization. Such findings can be used for droplet modeling for practical-scale simulations.

Droplet generation in micro-sieve dispersion device

Microfluidic devices with micro-sieve plate as the dispersion medium have been widely used for the mass production of emulsions. While unfortunately, few studies have so far been made for the droplet generation rules in those devices. In this work, the droplet generation processes in micro-sieve dispersion devices are investigated with specially designed micro-sieve pore arrays. The effects of channel structure, pore arrangement, and feeding method of dispersed phase on the average size and distribution of droplets are studied carefully. It is found the dimensionless average droplet diameters (dav/de) in micro-sieve dispersion devices can be represented by a linear relation with Ca−1/4 of continuous phase, the same as the scaling law in T-junction microchannels. The flow distribution among pores and the steric hindrance between droplets affect the diameter distribution of generated droplet very much. Monodispersed droplets with polydispersity index less than 5% can be made at Ca number larger than 0.01 and phase ratio (QD/QC) less than 1/6 in the present investigation.

Modelling of Kelvin–Helmholtz instability and splashing of melt layers from plasma-facing components in tokamaks under plasma impact

Plasma-facing components (PFCs) in tokamaks are exposed to high-heat loads during abnormal events such as plasma disruptions and edge-localized modes. The most significant erosion and plasma contamination problem is macroscopic melt splashes and losses from metallic divertor plates and wall materials into core plasma. The classical linear stability analysis is used to assess the initial conditions for development and growth of surface waves at the plasma–liquid metal interface. The maximum velocity difference and critical wavelengths are predicted. The effects of plasma density, surface tension and magnetic field on the stability of plasma–liquid tungsten flows are analytically investigated. The numerical modelling predicts that macroscopic motion and melt-layer losses involve the onset of disturbances on the surface of the tungsten melt layer with relatively long wavelengths compared with the melt thickness, the formation of liquid tungsten ligaments at wave crests and their elongation by the plasma stream with splitting of the bulk of the melt, and the development of extremely long, thin threads that eventually break into liquid droplets. Ejection of these droplets in the form of fine spray can lead to significant plasma contamination and enhanced erosion of PFCs. The numerical results advance the current understanding of the physics involved in the mechanism of melt-layer breakdown and droplet generation processes. These findings may also have implications for free surface liquid metal flows considered as the first wall in the design of several types of future fusion reactors.

Lattice Boltzmann simulation of droplet behaviour in microfluidic devices

We developed a lattice Boltzmann model to investigate the droplet dynamics in microfluidic devices. In our model, a stress-free boundary condition was proposed to conserve the total mass of flow system and improve the numerical stability for flows with low Reynolds number. The model was extensively validated by the benchmark cases including the Laplace's law, the static contact angles at solid surface, and the droplet deformation and breakup under simple shear flow. We applied our model to study the effects of the Pelcect number, the Capillary number and wettability on droplet formation. The results showed that the Peclet number has little effect on droplet size though it slightly affects the time of droplet formation. In the creeping flow regime, the Capillary number plays a dominating role in the droplet generation process. Wettability of fluids affects the position of droplet detachment, the droplet shape and size, and its impact becomes more significant when the Capillary number decreases. We also found that the hydrophobic surface generally can produce smaller droplet.

High-throughput laser printing of cells and biomaterials for tissue engineering

In parallel with ink-jet printing and bioplotting, biological laser printing (BioLP) using laser-induced forward transfer has emerged as an alternative method in the assembly and micropatterning of biomaterials and cells. This paper presents results of high-throughput laser printing of a biopolymer (sodium alginate), biomaterials (nano-sized hydroxyapatite (HA) synthesized by wet precipitation) and human endothelial cells (EA.hy926), thus demonstrating the interest in this technique for three-dimensional tissue construction. A rapid prototyping workstation equipped with an IR pulsed laser ( τ = 30 ns, λ = 1064 nm, f = 1–100 kHz), galvanometric mirrors (scanning speed up to 2000 mm s −1) and micrometric translation stages ( x, y, z) was set up. The droplet generation process was controlled by monitoring laser fluence, focalization conditions and writing speed, to take into account its mechanism, which is driven mainly by bubble dynamics. Droplets 70 μm in diameter and containing around five to seven living cells per droplet were obtained, thereby minimizing the dead volume of the hydrogel that surrounds the cells. In addition to cell transfer, the potential of using high-throughput BioLP for creating well-defined nano-sized HA patterns is demonstrated. Finally, bioprinting efficiency criteria (speed, volume, resolution, integrability) for the purpose of tissue engineering are discussed.

Droplet formation in a T-shaped microfluidic junction

Using a phase-field model to describe fluid/fluid interfacial dynamics and a lattice Boltzmann model to address hydrodynamics, two dimensional (2D) numerical simulations have been performed to understand the mechanisms of droplet formation in microfluidic T-junction. Although 2D simulations may not capture underlying physics quantitatively, our findings will help to clarify controversial experimental observations and identify new physical mechanisms. We have systematically examined the influence of capillary number, flow rate ratio, viscosity ratio, and contact angle in the droplet generation process. We clearly observe that the transition from the squeezing regime to the dripping regime occurs at a critical capillary number of 0.018, which is independent of flow rate ratio, viscosity ratio, and contact angle. In the squeezing regime, the squeezing pressure plays a dominant role in the droplet breakup process, which arises when the emerging interface obstructs the main channel. The droplet size depends on both the capillary number and the flow rate ratio, but is independent of the viscosity ratio under completely hydrophobic wetting conditions. In the dripping regime, the droplet size will be significantly influenced by the viscosity ratio as well as the built-up squeezing pressure. When the capillary number increases, the droplet size becomes less dependent on the flow rate ratio. The contact angle also affects the droplet shape, size, and detachment point, especially at small capillary numbers. More hydrophobic wetting properties are expected to produce smaller droplets. Interestingly, the droplet size is dependent on the viscosity ratio in the squeezing regime for less hydrophobic wetting conditions.

Comparison of micro-dispensing performance between micro-valve and piezoelectric printhead

In micro-dispensing applications, printhead activation mechanism, its design and operating parameters are integrated together to affect the droplet generation process. These factors give each printhead advantages and limitations over the others in specific fabrication. Hence, multiple printheads on micro level fabrication are preferred to perform multi-material dispensing task. In this paper, the mechanisms of two commonly used micro printheads, solenoid actuated micro-valve and piezoelectric printhead are discussed. Comprehensive experiments are conducted to characterize their performance and the results are analyzed so as to explore optimal droplet formation condition. With regards to the operational parameters’ influence on droplet formation, micro-valve is investigated in terms of pressure, and operational on time, and piezoelectric printhead is investigated based on pulse amplitude, and width of driving pulse. Nozzle size, a key design parameter in the two printheads, is also studied according to its influence on dispensing capability. To facilitate dispenser selection, the two printheads are compared based on droplet size, droplet stability, droplet velocity, and dispensing viscosity of successful ejection. Other factors such as chemical compatibility, time consumption in determining optimal condition and reliability of dispensing process are also reported to play an essential role in this selection. Our investigation on the relationship between related parameters and dispensing performance will not only benefit dispenser selection in multi-material dispensing application, but also build a solid background to develop multiple printhead system for fabrication of bioengineering components.

Predictive model on micro droplet generation through mechanical cutting

We describe the step-by-step formation process of picoliter to femtoliter volume of microdroplets by using a mechanical valve. An experiment-based theoretical model has been proposed through a parametric study of droplet formation in a microchannel with variations of the channel height, the working pressure to drive the liquids in the microchannels, and the viscosity of the dispensed phase. Three steps in the process of droplet generation have been depicted. The present study provides a clear understanding of the droplet generation process based on physical cutting method by using a mechanical valve and could be applied to advanced design for highly flexible droplet-based microfluidic systems.