An Investigation of Error Sources in Computational Fluid Dynamics Modelling of a Co-current Spray Dryer

The paper is focused on identifying error sources in computational fluid dynamics(CFD) predictions of a spray drying process. Seven groups of drying and atomisation parameters were selected for analysis and 13simulation trials were performed. The theoretical results were compared with experimental data and sensitivity of the simulation results to the analysed factors was determined. The following parameters affecting the accuracy of CFD spray modelling were found: gas turbulence model, particle dispersion, atomising air, initial parameters of atomisation and heat losses to the environment. A major difference in the errors committed during modelling of spray drying process for fine and coarse sprays was observed.

Fuel Spray Dynamic Characteristics of GDI High Pressure Injection System

In order to improve the fuel consumption and exhaust emission for gasoline engines,gasoline direct injection（GDI） system is spotlighted to solve these requirements.Thus,many researchers focus on the investigation of spray characteristics and the fuel formation of GDI injector.This paper presents a complete numerical and experimental characterization of transient gasoline spray from a high pressure injection system equipped with a modern single-hole electric controlled injector in a pressurized constant volume vessel.The numerical analysis is carried out in a one-dimensional model of fuel injection system which is developed in the AVL HYDSIM environment.The experimental analyses are implemented through a self-developed injection rate measurement device and spray evolution visualization system.The experimental results of injection rate and spray dynamics are taken to tune and validate the built model.The visualization system synchronize a high speed CMOS camera to obtain the spray structure,moreover,the captured images are taken to validate the injector needle lift process which is simulated in the model.The reliability of the built model is demonstrated by comparing the numerical results with the experimental data.The formed vortex structure at 0.8 ms is effectively disintegrated at 6.2 ms and the spray dynamics become rather chaotic.The fuel flow characteristics within injector nozzle extremely influence the subsequent spray evolution,and therefore this point should be reconsidered when building hybrid breakup GDI spray model.The spray tip speed reach the maximum at 1.18 ms regardless of the operation conditions and this is only determined by the injector itself.Furthermore,an empirical equation for the spray tip penetration is obtained and good agreement with the measured results is reached at a certain extent.This paper provides a methodology for the investigation of spray behavior and fuel distribution of GDI engine design.

Spray and Dynamic: Advanced Routing in Delay Tolerant Networks

This paper addresses the problem of routing in delay tolerant networks (DTNs). Delay tolerant networks are wireless networks where disconnections occur frequently due to mobility of nodes, failures of energy, the low density of nodes, or when the network extends over long distances. In these cases, traditional routing protocols that have been developed for mobile ad hoc networks prove to be ineffective to the extent of transmitting messages between nodes. To resolve this problem and improve the performance of routing in delay tolerant networks we propose a new routing protocol called Spray and Dynamic;this approach represents an improvement of the spray and wait protocol by combining it with the two protocols: MaxProp and the model of “transfer by delegation” (Custody Transfer). To implement our approach Spray and Dynamic, we have developed a DTN simulator according to DTN network architecture.

CFD simulation of ammonia-based CO_2 absorption in a spray column

A comprehensive computational fluid dynamics（CFD） model is developed based on the gas-liquid two-phase hydrodynamics,gas-liquid mass-transfer theory and chemical reaction kinetics,and the ammonia-based CO2 absorption in a spray column is numerically studied.The Euler-Lagrange model is applied to describe the behavior of gas-liquid twophase flowand heat transfer.The dual-film theory and related correlations are adopted to model the gas-liquid mass transfer and chemical absorption process.The volatilization model of multi-component droplet is utilized to account for ammonia slippage.The effect of operation parameters on CO2 removal efficiency is numerically studied.The results showa good agreement with the previous experimental data,proving the validity of the proposed model.The profile studies of gasphase velocity and CO2 concentration suggest that the flowfield has a significant impact on the CO2 concentration field.Also,the local CO2 absorption rate is influenced by both local turbulence and the local liquid-gas ratio.Furthermore,the velocity field of gas phase is optimized by the method of adjusting the orifice plate,and the results showthat the CO2 removal efficiency is improved by approximately 4%.

Characterization of microstructure evolution and mechanical properties of the spray-deposited AZ31 magnesium alloy

The cylindrical billets of a Mg-3Al-1Zn （AZ31） alloy were synthesized by spray deposition processing. The microstructure evolution and mechanical properties of the alloy were investigated. The results reveal that the microstructure of the AZ31 alloy is refined significantly by spray deposition processing. A homogeneous and equiaxial-grain structure with an average grain size of 17 μm is obtained. Further grain refinement with an average grain size of 5 μm is attributed to dynamic recrystallization during extrusion processing. The great increase in the density of grain boundary nucleation sites by the finer initial grain sizes makes the dislocation pile-ups near subgrain boundaries being absorbed easily by the boundaries, resulting in an accelerated recrystallization process. The average tensile ultimate and yield strengths of the extruded rods are 321 MPa and 237 MPa, respectively, with an elongation of 15.2% at room temperature, which are remarkably higher than those of the conventional as-cast AZ31 alloy.

Spray Evaporation of Different Liquids in a Drying Chamber--Effect on Flow, Heat and Mass Transfer Performances

Almost without exception literature data and modeling effort are understandably devoted to water as the sprayed liquid since it constitutes the most common liquid used in spray drying applications. In selected applications, however, the liquid making up the solution or suspension may not be water. The objective of this work is to examine the differences in flow patterns, thermal behavior and drying rates caused by different liquids having different thermo-physical properties spray into a spray dryer using a computational fluid dynamic model.Numerical experiments were carried out for water (base case), ethyl alcohol and isopropyl alcohol-the latter two as model non-aqueous liquids. The chamber geometry was cylinder type with a co-current axial pressure nozzle and also an axial central exit so that the configuration is two dimensional and axi-symmetric. It is shown that the liquid properties can have major influence on the thermal field, droplet trajectories, residence times and overall evaporation capacity when all parameters of the problem are held fixed. Deviations from the single phase turbulent airflow in the same chamber without spray are different for the three liquids examined.

Hot deformation behavior of a spray-deposited AZ31 magnesium alloy

The flow stress behavior of an as-spray-deposited AZ31 magnesium alloy with fine grains was investigated by means of compression tests with a Gleeble 1500 thermal mechanical simulator at isothermal constant strain rates of 0.01, 0.1, 1.0, and 10 s^-1; the testing temperatures ranged from 623 to 723 K. It is demonstrated that a linear equation can be fitted between the Zemer-Hollomon parameter Z and stress in a double-log scale. The effect of deformation parameters on the behavior of recrystallization was analyzed. Dynamic recrystallization （DRX） generally occurs at a higher temperature and at a lower strain rate. The constitutive equation of the spray-deposited AZ31 magnesium alloy is presented by calculating the deformation activation energy （199.8 kJ·mol^-1）. The as-spray-formed AZ31 alloy is easier for DRX nucleation at elevated temperatures due to the fine grain, which provides a large amount of nucleation sites and a high-diffusivity path for the atom.

Predominance of inhalation route in short-range transmission of respiratory viruses:Investigation based on computational fluid dynamics

During the coronavirus disease 2019 pandemic,short-range virus transmission has been observed to have a higher risk of causing infection than long-range virus transmission.However,the roles played by the inhalation and large droplet routes cannot be distinguished in practice.A recent analytical study revealed the predominance of short-range inhalation over the large droplet spray route as causes of respiratory infections.In the current study,short-range exposure was analyzed via computational fluid dynamics(CFD)simulations using a discrete phase model.Detailed facial membranes,including eyes,nostrils,and a mouth,were considered.In CFD simulations,there is no need for a spherical approximation of the human head for estimating deposition nor the“anisokinetic aerosol sampling”approximation for estimating inhalation in the analytical model.We considered two scenarios(with two spheres[Scenario 1]and two human manikins[Scenario 2]),source-target distances of 0.2 to 2 m,and droplet diameters of 3 to 1,500μm.The overall CFD exposure results agree well with data previously obtained from a simple analytical model.The CFD results confirm the predominance of the short-range inhalation route beyond 0.2 m for expiratory droplets smaller than 50μm during talking and coughing.A critical droplet size of 87.5μm was found to differentiate droplet behaviors.The number of droplets deposited on the target head exceeded those exposed to facial membranes,which implies a risk of exposure through the immediate surface route over a short range.

Hot deformation behavior of Al-9.0Mg-0.5Mn-0.1Ti alloy based on processing maps

Hot deformation behavior of extrusion preform of the spray-formed Al-9.0Mg-0.5Mn-0.1Ti alloy was studied using hot compression tests over deformation temperature range of 300-450 ℃ and strain rate range of 0.01-10 s-1. On the basis of experiments and dynamic material model, 2D processing maps and 3D power dissipation maps were developed for identification of exact instability regions and optimization of hot processing parameters. The experimental results indicated that the efficiency factor of energy dissipate （η） lowered to the minimum value when the deformation conditions located at the strain of 0.4, temperature of 300 ° C and strain rate of 1 s-1. The softening mechanism was dynamic recovery, the grain shape was mainly flat, and the portion of high angle grain boundary （〉15°） was 34%. While increasing the deformation temperature to 400 ° C and decreasing the strain rate to 0.1 s-1, a maximum value of η was obtained. It can be found that the main softening mechanism was dynamic recrystallization, the structures were completely recrystallized, and the portion of high angle grain boundary accounted for 86.5%. According to 2D processing maps and 3D power dissipation maps, the optimum processing conditions for the extrusion preform of the spray-formed Al？9.0Mg？0.5Mn？0.1Ti alloy were in the deformation temperature range of 340-450 ° C and the strain rate range of 0.01-0.1 s-1 with the power dissipation efficiency range of 38%？43%.

Molecular tagging techniques and their applications to the study of complex thermal flow phenomena

This review article reports the recent progress in the development of a new group of molecule-based flow diagnostic techniques, which include molecular tag- ging velocimetry （MTV） and molecular tagging thermometry （MTT）, for both qualitative flow visualization of thermally induced flow structures and quantitative whole-field mea- surements of flow velocity and temperature distributions. The MTV and MTT techniques can also be easily combined to result in a so-called molecular tagging velocimetry and ther- mometry （MTV＆T） technique, which is capble of achieving simultaneous measurements of flow velocity and temperature distribution in fluid flows. Instead of using tiny particles, the molecular tagging techniques （MTV, MTT, and MTV＆T） use phosphorescent molecules, which can be turned into long-lasting glowing marks upon excitation by photons of appropriate wavelength, as the tracers for the flow veloc- ity and temperature measurements. The unique attraction and implementation of the molecular tagging techniques are demonstrated by three application examples, which include： （1） to quantify the unsteady heat transfer process from a heated cylinder to the surrounding fluid flow in order to exam- ine the thermal effects on the wake instabilities behind the heated cylinder operating in mixed and forced heat convec- tion regimes, （2） to reveal the time evolution of unsteady heat transfer and phase changing process inside micro-sized, icing water droplets in order to elucidate the underlying physics pertinent to aircraft icing phenomena, and （3） to achievesimultaneous droplet size, velocity and temperature measure- ments of ＂in-flight＂ droplets to characterize the dynamic and thermodynamic behaviors of flying droplets in spray flows.

Topology optimization of reactive material structures for penetrative projectiles

Recently,reactive materials have been developed for penetrative projectiles to improve impact resistance and energy capacity.However,the design of a reactive material structure,involving shape and size,is challenging because of difficulties such as high non-linearity of impact resistance,manufacturing limitations of reactive materials and high expenses of penetration experiments.In this study,a design optimization methodology for the reactive material structure is developed based on the finite element analysis.A finite element model for penetration analysis is introduced to save the expenses of the experiments.Impact resistance is assessed through the analysis,and result is calibrated by comparing with experimental results.Based on the model,topology optimization is introduced to determine shape of the structure.The design variables and constraints of the optimization are proposed considering the manufacturing limitations,and the optimal shape that can be manufactured by cold spraying is determined.Based on the optimal shape,size optimization is introduced to determine the geometric dimensions of the structure.As a result,optimal design of the reactive material structure and steel case of the penetrative projectile,which maximizes the impact resistance,is determined.Using the design process proposed in this study,reactive material structures can be designed considering not only mechanical performances but also manufacturing limitations,with reasonable time and cost.

Achieving strength-ductility synergy in cold spray additively manufactured Al/B4C composites through a hybrid post-deposition treatment

Cold spray additive manufacturing(CSAM) provides a potential solid state manufacturing route to fabricate variety of aluminum matrix composites(AMCs) with reduced possibility of undesired chemical reactions and residual thermal stresses. This study presents a hybrid(i.e. hot compression + hot rolling)post-deposition treatment to reinvigorate the mechanical properties of cold spray additively manufactured Al/B4 C composites. The as-deposited samples were initially subjected to 30% thickness reduction via hot compression treatment at 500°C followed by a hot rolling treatment with 40% thickness reduction in 2 passes. Electron backscatter diffraction(EBSD) and high resolution transmission electron microscopy(HRTEM) results revealed that after hybrid post-deposition treatment(involving 70%accumulative thickness reduction), the aluminum grains in the matrix were extensively refined due to simultaneous operation of continuous dynamic recrystallization(CDRX) and geometric dynamic recrystallization(GDRX). Furthermore, interfacial defects were remarkably reduced while the nature of Al/Al and Al/B4C interfacial bonding was changed from sheer mechanical interlocking to metallurgical bonding which facilitated efficient transference of applied load to uniformly dispersed bimodal B4C particles. As a result, ultimate tensile strength(UTS) and elongation(EL) of the as-deposited sample were simultaneously improved from 37 to 185 MPa and 0.3% to 6.2%, respectively.

Microstructural Characterization of Spray Formed FGH4095 Superalloy During Hot Deformation

In order to study the hot workability and to optimize the processing parameters for spray formed FGH4095 superalloy, thermal compression tests for spray formed FGH4095 superalloy have been finished by using a Gleeble 1500 thermal simulated test machine at the strain rates of 0.01-10.0 s 1 and temperatures of 1 050-1 140 ℃. The effects of strain rate and deformation temperature on the true stress-true strain curves and microstructure evolution were investigated. The results show that the generation of dynamic recrystallization （DRX） depends sensitively on deformation temperature. When the temperature was lower than 1080 ~C, long and＂ narrow necklace grains were shown in the microstructure. When the temperature increased to 1 140 ℃, new recrystallization grains were genera-ted. The size and shape of X＇ precipitates in the grains have a very important effect as factors of hindering sufficient migration of dislocations on plastic deformation. The result of thermal processing map is in accord with the micro-structure observation, and the best material thermal processing temperature is above 1 128 ℃.

Microstructuring of titanium surfaces with plasma-modified titanium particles by cold spraying

Although the deposition mechanisms of the cold spray process are well studied, few reports regarding the use of surface-modified particles exist. Herein, titanium particles 3-39 μm in size and with an angular shape were modified in a plasma-enhanced chemical vapor deposition process in Ar, Ar-C2H2, and N2 plasmas. After Ar-C2H2 and N2 treatments, the respective presence of TiC and TiN on the particle surface was confirmed via transmission electron microscopy and energy-dispersive X-ray, X-ray photoelectron, and Raman spectroscopies. The powders were deposited on titanium substrates by cold spray experiments, where unmodified particles up to 10(xm in size exhibited a successful surface bon ding. This finding was described by an existing analytical model, whose parameters were achieved by computational fluid dynamics simulations taking the particle shape factor into account:. A good deposition of plasma-modified particles up to 30 μm in size was experimentally observed, exhibiting an upper size limit larger than that predicted by the model. Higher surface roughness values were found for plasmamodified particles, as determined by 3D scanning electron microscopy. The water contact angle indicated that argon treatment influenced the wettability. Tribological tests showed a decrease of the initial friction coefficient from 0.53 to 0.47 by microstructuring.

A Review of Engine Fuel Injection Studies Using Synchrotron Radiation X-ray Imaging

Fuel spray characteristics directly determine the formation pattern and quality of the fuel/air mixture in an engine,and thus affect the combustion process.For this reason,the improvement and optimization of fuel injection systems is crucial to the development of engine technologies.The fuel jet breakup and atomization process is a complex liquid-gas two-phase turbulent flow system that has not yet been fully elucidated.Owing to the limitations of standard optical measurement techniques,the spray breakup mechanism and its interaction with the nozzle internal flow are still unclear.However,in recent years synchrotron radiation(SR)X-ray imaging technologies have been widely applied in engine fuel injection studies because of the higher energy and brilliance of third-generation SR light sources.This review provides a brief introduction to the development of SR technology and compares the critical parameters of the primary third-generation SR light sources available worldwide.The basic principles and applications of various X-ray imaging technologies with regard to nozzle internal structure measurements,visualization of in-nozzle flow characteristics and quantitative analyses of near-field spray transient dynamics are examined in detail.

Effects of xanthan gum on atomization and deposition characteristics in water and Silwet 408 aqueous solution

In order to investigate the effects of viscosity on spray formation and utilization of pesticide,different concentrations of xanthan gum(XG)were added into water and 0.1%Silwet 408 aqueous solution.Droplet size,relative span(RS),fan angle,length of breakup and maximum retention(Rm)were measured with the LU120-02 nozzle spraying under the pressure of 0.3 MPa.The dynamic spreading of the different solutions on maize leaves was tested using a 5μL micro-injector.The results showed:VMD,RS,length of breakup and Rm went up as the increasing of XG concentration in the range of 0-0.5%with the same solution,while the fan angle of nozzle and spreading area on maize leaf showed the opposite tendency.Silwet 408 could reduce the surface tension of liquid,which could alter the dominant mode of spray formation and lead to earlier sheet breakup,especially in low viscosity solutions.Under the same concentration of XG the addition of Silwet 408 could reduce the RS of drop size spectrum but has no effect on VMD or fan angle.In water solution,there was no difference with different concentrations of XG in the spreading time on maize leaf.Besides,in the 0.1%Silwet 408 aqueous solution,the spraying time and area were several-fold of that in water with same XG concentration.Moreover,with the same XG concentration,the smaller surface tension liquid indicated lower Rm,and the difference was magnified as the concentration increases.This work has demonstrated that initial spray characteristics such as droplet size and RS,fan angle,length of breakup,Rm and spreading area can vary depending on the viscosity of spray liquids.Therefore,by transforming the viscosity of the spray liquid to adjust the droplet spectrum to reduce drift,increasing the Rm and spreading area to improve liquid utilization and reduce the usage of pesticides.