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1. Atomization of High Viscosity Liquids Using a Two-Fluid Counterflow Nozzle: Experiments and Modeling

   https://doi.org/10.1115/GT2020-15691  

   Rangarajan, Roshan; Zhang, Hongyuan; Strykowski, Paul J.; Hoxie, Alison; Yang, Suo; Srinivasan, Vinod (September 2020, ASME Turbo Expo 2020: Turbomachinery Technical Conference and Exposition)

   null (Ed.)

   We study the enhanced atomization of viscous liquids by employing a novel two-fluid atomizer. The nozzle establishes a countercurrent flow configuration in which the gas and liquid are directed in opposite directions, establishing a two-phase mixing layer. Detailed measurements of droplet size distributions were carried out using laser shadowgraphy, along with high speed flow visualization. The measurements suggest that the liquid emerges as a spray with little further secondary atomization. The performance of this nozzle is compared to the ‘flow-blurring’ nozzle studied by other investigators for four test liquids of viscosity ranging from 1 to 133.5 mPa.s. The counterflow nozzle produces a spray whose characteristics are relatively insensitive to fluid viscosity over the range studied, for gas-liquid mass flow ratios between 0.25 and 1. To gain insight into the mixing process inside the nozzle, simulations are carried out using an Eulerian-Eulerian Volume of Fluid (VoF) approach for representative experimental conditions. The simulation reveals the detailed process of self-sustained flow oscillations and the physical mechanism that generate liquid filaments and final droplets. 

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2. High-fidelity simulation of a rotary bell atomizer with electrohydrodynamic effects

   Krisshna, Venkata; Owkes, Mark (August 2021, ICLASS 2021, 15th Triennial International Conference on Liquid Atomization and Spray Systems)

   Rotary Bell Atomizers (RBA) are extensively used as paint applicators in the automotive industry. Atomization of paint is achieved by a bell cup rotating at speeds of 40k-60k RPM in the presence of a background electric field. Automotive paint shops amount up to 70% of the total energy costs [Galitsky et. al., 2008], 50% of the electricity demand [Leven et. al., 2001] and up to 80% of the environmental concerns [Geffen et al., 2000] in an automobile manufacturing facility. The atomization process in an RBA affects droplet size and velocity distribution which subsequently control transfer efficiency and surface finish quality. Optimal spray parameters used in industry are often obtained from expensive trial-and-error methods. In this work, three-dimensional near-cup atomization (primary and secondary breakup) are simulated computationally using a high-fidelity volume-of-fluid transport scheme that includes an electrohydrodynamic effects. The influence of fluid properties (viscosity ratio, flow rate and charge density), nozzle rotation rate and bell potential on atomization are investigated by performing a parametric study. This cost-effective method of research aims to identify the ideal spray parameters to achieve maximum transfer efficiency. 

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3. Investigating atomization characteristics in an electrostatic rotary bell atomizer

   https://doi.org/10.1016/j.ijmultiphaseflow.2024.104814  

   Krisshna, Venkata; Owkes, Mark (May 2024, International Journal of Multiphase Flow)

   Electrostatic rotary bell atomizers are commonly used in several engineering applications, including the automobile industry. A high-speed rotating nozzle operating in a strong background electric field atomizes paint into charged droplets that range from a few micrometers to tens of micrometers in diameter. The atomization process directly determines the droplet size and droplet charge distributions which subsequently control the transfer efficiency and the surface finish quality. We have previously developed a tool to perform high fidelity simulations of near-bell atomization with electrohydrodynamic effects. In this work, we perform simulations employed with a droplet ancestry extraction tool to analyze previously inaccessible information and understand the physical processes driving atomization. We find that the electric field accelerates breakup processes and enhances secondary atomization. The total number of droplets, the ratio of secondary to primary droplets, and the ratio of coalescence to breakup activity are all much higher when operating in an electric field. We analyze the droplet velocity, local Weber number and charge density statistics to understand the complex physics in electrically assisted breakup. The results of the study have helped us gain insights into the physics of atomization in electrostatic rotary sprays. 

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4. Visualization of Internal Flow Dynamics in Counterflow Atomizers Using X-Ray Diagnostics and Laser Shadowgraphy

   Hoxie, A.; Srinivasan, V.; Johnson, E.; Kastengren, A. (May 2022, ILASS-Americas 32nd Annual Conference on Liquid Atomization and Spray Systems)

   Experiments were carried out to observe the flow inside counterflow atomizers over a range of operating conditions and fluid properties. Liquids used were water and propylene glycol, while the gas was either air or helium. Liquid flow rates ranged from 10 ml/min to 40 ml/min, with gas liquid ratio (GLR) ranging from 0.1 to 0.6. The primary experiments used the 7-BM line of the Advanced Photon Source in Argonne National Laboratories with a 2.6 mm atomizer produced from (Poly)Ethyl-Ether-Ketone (PEEK). The X-Ray beam was operated in phase contrast mode, leading to interference patterns near the gas-liquid interface and enabling a qualitative understanding of the flow structure. Complementary optical work applied laser shadowgraphy to a 1 mm orifice atomizer constructed with quartz capillary tubing. A diffuse pulsed Nd:YAG laser backlight captured instantaneous gas-liquid interface positions in the internal flow. With both techniques, two distinct flow behaviors are observed corresponding to low and high GLR values. At low GLR, the inertia of the injected gas is insufficient to penetrate the liquid downflow. The gas stream entering the mixing chamber in the upstream direction is immediately deflected by the denser liquid and enters the discharge tube around a central liquid jet, which is sheared and accelerated by the surrounding gas, leading to breakup. A distinct frequency of jet breakup is observed inside the discharge tube, with the liquid jet oscillating and fragmenting against the walls. The situation at high GLR is quite different, however, as the incoming gas stream asymmetrically penetrates upstream into the mixing chamber, taking the form of a high-speed jet confined along one wall, and displaying a flapping instability as it encounters the liquid flowing downstream. This flapping causes violent mixing, resulting in a highly disturbed interface, along with the generation of liquid ligaments and gas bubbles. This two-phase mixture enters the discharge tube with no liquid jet formation evident for this case. The transition between these two regimes is explored by changing the liquid viscosity and gas molar mass, and weak sensitivity to fluid properties is observed. Further, quantitative image analysis techniques applied to the low and high GLR cases allow extraction of the frequencies of the liquid jet in the discharge tube at low GLR, as well as the flapping mode at high GLR. 

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5. The effect of nozzle internal flow on spray atomization

   https://doi.org/10.1177/1468087419875843  

   Agarwal, Arpit; Trujillo, Mario_F (September 2019, International Journal of Engine Research)

   The effect of nozzle surface features on the overall atomization behavior of a liquid jet is analyzed in the present computational work by adopting three representative geometries, namely a single X-ray tomography scan of the Engine Combustion Network’s Spray A nozzle (Unprocessed), a spline reconstruction of multiple scans (Educated), and a purely external flow configuration. The latter configuration is often used in fundamental jet atomization studies. Numerically, the two-phase flow is solved based on algebraic volume-of-fluid methodology utilizing the OpenFoam solver, interFoam. Quantitative characterization of the surface features concerning the first two geometries reveals that while both of them have similar levels of cylindrical asymmetries, the nozzle configuration pertaining to the Unprocessed geometry has much larger surface features along the streamwise direction than the Educated geometry. This produces for the Unprocessed configuration a much larger degree of non-axial velocity components in the flow exiting the orifice and also a more pronounced disturbance of the liquid surface in the first few diameters downstream of the nozzle orifice. Furthermore, this heightened level of surface destabilization generates a much shorter intact liquid core length, that is, it produces faster primary atomization. The surprising aspect of this finding is that the differences between the Unprocessed and Educated geometries are of [Formula: see text](1) μm, and they are able to produce [Formula: see text](1) mm effects in the intact liquid core length. In spite of more pronounced atomization for the Unprocessed geometry, the magnitude of the turbulent liquid kinetic energy is roughly the same as the Educated geometry. This highlights the important role of mean field quantities, in particular, non-axial velocity components, in precipitating primary atomization. At the other end of the spectrum, the external-only configuration has the mildest level of surface disturbances in the near field resulting in the longest intact liquid core length. 

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