A study on converging-diverging nozzle design for supersonic spraying of liquid droplets toward nanocoating applications

IF 2.4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING
Semih Akin, Puyuan Wu, Chandra Nath, Jun Chen, M. Jun
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Abstract

Supersonic cold spraying of liquid droplets containing functional nanomaterials is of particular interest in advanced thin-film coating, that enabling high-adhesion strength particle deposition. In cold spraying, the optimum design of the supersonic nozzle is essential for accelerating particles to desired velocities. However, research on the supersonic nozzle design for liquid droplets is limited. Thus, we thoroughly investigate the influence of nozzle geometrical parameters (i.e., throat diameter, exit diameter, divergent length) on droplets acceleration by numerical modeling followed by experimental validation, and a case study on surface coating application. Two-phase flow modeling was used to predict droplets' behavior in continuous gas flow for different nozzle configurations. The results show that the nozzle expansion ratio - a function of throat and exit diameters - has a significant influence on droplet velocity, followed by divergent length. In particular, to correctly accelerate “low-inertia liquid droplets”, optimum nozzle expansion ratio for an axisymmetric convergent-divergent nozzle is found to be in a range of 1.5-2.5 for different sets of parameters, which is different than the recommended expansion ratio (i.e., 5-9) for cold spraying of conventional “metal” particles. Based on the simulation results, an optimal design of supersonic nozzle is selected and prototyped for the experimental studies. Numerical modeling results are validated by particle image velocimetry (PIV) measurements. Moreover, coating experiments confirm the adaptability of the optimized nozzle for supersonic cold spraying of droplets containing nanoparticles, which thereby has the potential for rapid production of advanced thin films.
用于纳米涂层应用的液滴超声喷涂的会聚-发散喷嘴设计研究
含有功能性纳米材料的液滴的超音速冷喷涂在先进的薄膜涂层中尤其令人感兴趣,这种涂层能够实现高粘附强度的颗粒沉积。在冷喷涂中,超音速喷嘴的优化设计对于将颗粒加速到所需速度至关重要。然而,对液滴超音速喷嘴设计的研究是有限的。因此,我们通过数值建模、实验验证和表面涂层应用的案例研究,深入研究了喷嘴几何参数(即喉部直径、出口直径、发散长度)对液滴加速的影响。两相流模型用于预测不同喷嘴配置下连续气流中液滴的行为。结果表明,喷嘴膨胀比(喉部和出口直径的函数)对液滴速度有显著影响,其次是发散长度。特别是,为了正确加速“低惯性液滴”,对于不同的参数组,轴对称收敛-发散喷嘴的最佳喷嘴膨胀比在1.5-2.5的范围内,这与传统“金属”颗粒冷喷涂的推荐膨胀比(即5-9)不同。基于仿真结果,选择了超声速喷嘴的优化设计方案,并对其进行了实验研究。数值模拟结果通过粒子图像测速仪(PIV)测量得到验证。此外,涂层实验证实了优化喷嘴对含有纳米颗粒的液滴的超音速冷喷涂的适应性,从而具有快速生产先进薄膜的潜力。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
CiteScore
6.80
自引率
20.00%
发文量
126
审稿时长
12 months
期刊介绍: Areas of interest including, but not limited to: Additive manufacturing; Advanced materials and processing; Assembly; Biomedical manufacturing; Bulk deformation processes (e.g., extrusion, forging, wire drawing, etc.); CAD/CAM/CAE; Computer-integrated manufacturing; Control and automation; Cyber-physical systems in manufacturing; Data science-enhanced manufacturing; Design for manufacturing; Electrical and electrochemical machining; Grinding and abrasive processes; Injection molding and other polymer fabrication processes; Inspection and quality control; Laser processes; Machine tool dynamics; Machining processes; Materials handling; Metrology; Micro- and nano-machining and processing; Modeling and simulation; Nontraditional manufacturing processes; Plant engineering and maintenance; Powder processing; Precision and ultra-precision machining; Process engineering; Process planning; Production systems optimization; Rapid prototyping and solid freeform fabrication; Robotics and flexible tooling; Sensing, monitoring, and diagnostics; Sheet and tube metal forming; Sustainable manufacturing; Tribology in manufacturing; Welding and joining
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