VISUALIZATION AND CHARACTERIZATION OF ULTRASONIC CAVITATING ATOMIZER AND OTHER AUTOMOTIVE PAINT SPRAYERS USING INFRARED THERMOGRAPHY

The disintegration of a liquid jet emerging from a nozzle has been under investigation for several decades. A direct consequence of the liquid jet disintegration process is droplet formation. The breakup of a liquid jet into discrete droplets can be brought about by the use of a diverse forcing mechanism. Cavitation has been thought to assist the atomization process. Previous experimental studies, however, have dealt with cavitation as a secondary phenomenon assisting the primary atomization mechanism. In this dissertation, the role of the energy created by the collapse of cavitation bubbles, together with the liquid pressure perturbation is explicitly configured as a principal mechanism for the disintegration of the liquid jet. A prototype of an atomizer that uses this concept as a primary atomization mechanism was developed and experimentally tested using water as working fluid. The atomizer fabrication process and the experimental characterization results are presented. The parameters tested include liquid injection pressure, ultrasonic horn tip frequency, and the liquid flow rate. The experimental results obtained demonstrate improvement in the atomization of water. To fully characterize the new atomizer, a novel infrared thermography-based technique for the characterization and visualization of liquid sprays was developed. The technique was tested on the new atomizer and two automotive paint applicators. The technique uses an infrared thermography-based measurement in which a uniformly heated background acts as a thermal radiation source, and an infrared camera as the receiver. The infrared energy emitted by the source in traveling through the spray is attenuated by the presence of the droplets. The infrared intensity is captured by the receiver showing the attenuation in the image as a result of the presence of the spray. The captured thermal image is used to study detailed macroscopic features of the spray flow field and the evolution of the droplets as they are transferred from the applicator to the target surface. In addition, the thermal image is post-processed using theoretical and empirical equations to extract information from which the liquid volume fraction and number density within the spray are estimated

Study of Near-Cup Droplet Breakup of an Automative Electrostatic Rotary Bell (ESRB) Atomizer Using High-Speed Shadowgraph Imaging

Electrostatic Rotary bell (ESRB) atomizers are used as the dominant means of paint application by the automotive industry. They utilize the high rotational speed of a cup to induce primary atomization of a liquid along with shaping air to provide secondary atomization and transport. In order to better understand the fluid breakup mechanisms involved in this process, high-speed shadowgraph imaging was used to visualize the edge of a serrated rotary bell at speeds varying between 5000 and 12,000 RPM and with a water flow rate of 250 ccm. A multi-step image processing algorithm was developed to differentiate between ligaments and droplets during the primary atomization process. The results from this experiment showed that higher bell speeds resulted in a 26.8% reduction in ligament and 22.3% reduction in droplet Sauter Mean Diameters (SMD). Additionally, the ligament (ranging from 40 to 400 μm) diameters formed bimodal distributions, while the droplet (ranging from 40 to 300 μm) diameters formed a normal distribution. Velocities were also measured using particle tracking velocimetry, in which size-dependent velocities could then be computed. Droplet velocities were affected more by rotational speed than droplet SMD, while ligaments were affected by other factors than the rotational speed and ligament SMD

INKJET PRINTING: FACING CHALLENGES AND ITS NEW APPLICATIONS IN COATING INDUSTRY

This study is devoted to some of the most important issues for advancing inkjet printing for possible application in the coating industry with a focus on piezoelectric droplet on demand (DOD) inkjet technology. Current problems, as embodied in liquid filament breakup along with satellite droplet formation and reduction in droplet sizes, are discussed and then potential solutions identified. For satellite droplets, it is shown that liquid filament break-up behavior can be predicted by using a combination of two pi-numbers, including the Weber number, We and the Ohnesorge number, Oh, or the Reynolds number, Re, and the Weber number, We. All of these are dependent only on the ejected liquid properties and the velocity waveform at the print-head inlet. These new criteria are shown to have merit in comparison to currently used criteria for identifying filament physical features such as length and diameter that control the formation of subsequent droplets. In addition, this study performs scaling analyses for the design and operation of inkjet printing heads. Because droplet sizes from inkjet nozzles are typically on the order of nozzle dimensions, a numerical simulation is carried out to provide insight into how to reduce droplet sizes by employing a novel input waveform impressed on the print-head liquid inflow without changing the nozzle geometry. A regime map for characterizing the generation of small droplets based on We and a non-dimensional frequency, Ω is proposed and discussed. In an attempt to advance inkjet printing technology for coating purposes, a prototype was designed and then tested numerically. The numerical simulation successfully proved that the proposed prototype could be useful for coating purposes by repeatedly producing mono-dispersed droplets with controllable size and spacing. Finally, the influences of two independent piezoelectric characteristics - the maximum head displacement and corresponding frequency, was investigated to examine the quality of filament breakup quality and favorable piezoelectric displacements and frequencies were identified

CHARACTERIZATION OF ROTARY BELL ATOMIZERS THROUGH IMAGE ANALYSIS TECHNIQUES

Three methods were developed to better understand and characterize the near-field dynamic processes of rotary bell atomization. The methods were developed with the goal of possible integration into industry to identify equipment changes through changes in the primary atomization of the bell. The first technique utilized high-speed imaging to capture qualitative ligament breakup and, in combination with a developed image processing technique and PIV software, was able to gain statistical size and velocity information about both ligaments and droplets in the image data. A second technique, using an Nd:YAG laser with an optical filter, was used to capture size statistics at even higher rotational speeds than the first technique, and was utilized to find differences between serrated and unserrated bell ligament and droplet data. The final technique was incorporating proper orthogonal decomposition (POD) into image data of a side-profile view of a damaged and undamaged bell during operation. This was done to capture differences between the data sets to come up with a characterization for identifying if a bell is damaged or not for future industrial integration

EFFECT OF HEATING AND IONIZATION OF FOUR ATOMIZING GASES ON THE SPRAY CHARACTERISTICS OF A HIGH VOLUME LOW PRESSURE SPRAY ATOMIZER

The disintegration of a liquid jet emerging from a nozzle by a high speed gas stream has been under investigation of several decades. A result of the liquid jet disintegration is droplet formation. This process is referred to as atomization. Industrial applications use atomization as a method for applying coatings to substrates. It has been reported that the use of other atomizing gases instead of compressed plant air will positively affect paint droplet size distributions, spray patterns and finish qualities; furthermore, the ionization and heating of the atomizing gas was reported to positively affect finish qualities. Although ionization techniques have been studied in the past, a lack of specific information remains about how ionization actually affects droplet formation and size, and finish quality. To determine the effect of the different atomizing gases, heating, and ionization several methods were used. The droplet size distribution of the spray was captured with the use of laser diffraction, while the large-scale characteristics of the flow were recorded with Infrared thermography. In the process, a novel method was developed for measuring the secondary droplet breakup in the spray

Oil droplet breakup during pressure swirl atomization of food emulsions: Influence of atomization pressure and initial oil droplet size

Atomization of emulsions with pressure swirl atomizers is a common task in food process engineering. Especially in spray drying processes for food materials like dairy products, it is the technology of choice. During atomization, emulsions are subjected to high stresses, which can lead to deformation and breakup of the dispersed droplets. In this study, the influence of atomization pressure (5–20 MPa) and initial oil droplet size (0.26, 3.1, and 20.8 μm) on the oil droplet breakup during atomization of food based oil‐in‐water emulsions with pressure swirl atomizers was investigated. It was shown that a significant oil droplet breakup takes place upon atomization. The size of oil droplets with an initial value of 3.1 and 20 μm was reduced up to 0.36 μm. No breakup of oil droplets with an initial value of 0.26 μm was observed. The breakup was highly dependent on the atomization pressure. The results were analyzed based on existing knowledge on droplet breakup in laminar flow. A concept to estimate capillary numbers during atomization was developed based on common models from different applications. The results of this study can be used to control the resulting oil droplet size after atomization with pressure swirl atomizers. Practical application: Spray drying of emulsions is a widely used process in the food industry to produce products with encapsulated oily components. Product examples include infant formula, milk powder, and the encapsulation of aroma and coloring compounds. Breakup of the oil droplets during the atomization step of spray drying can change a previously adjusted and desired oil droplet size. As the oil droplet size in the final product can be responsible for several properties like sensorial aspects and stability, a control of oil droplet breakup is essential. Pressure swirl atomizers are widely used in industrial applications as atomization devices. In this study, oil droplet breakup during atomization with these atomizers was investigated. The findings in this study allow a better control of the oil droplet size during atomization in practical applications

Fundamental Analysis of Liquid Atomization by Fuel Slingers in Small Gas Turbines

Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/76266/1/AIAA-2002-3183-108.pd

NUMERICAL AND SCALING STUDY ON APPLICATION OF INKJET TECHNOLOGY TO AUTOMOTIVE COATING

A thorough literature review identified lack of precision control over quality of droplets generated by the currently available industrial sprayers and a growing need for higher quality droplets in the coating industry. Particularly, lack of knowledge and understanding in continuous inkjets (CIJ) and drop-on-demand (DOD) technologies is identified as significant. Motivated by these needs, this dissertation is dedicated to computational fluid dynamics (CFD) and scaling studies to improve existing inkjet technologies and develop new designs of efficient coating with single and/or multiple piezoelectric sensors to produce on-demand droplets. This dissertation study aims at developing a new DOD type coating technology, but it required understanding the effects of paint viscosity on droplet generation mechanism, an effective droplet delivery method to the coating surface, painted surface quality and control system of the DOD among others. Waterborne (WB) paints are chosen as the working liquid to identify three different DOD designs capable of creating a stream of mono-dispersed droplets. Volume-of-fluids (VOF) multiphase model explored the droplet creation process and effects of various parameters on the droplets’ quality. The law approach scaling analysis identified scaling laws to scale up these numerical results conduced for the laboratory-scale DOD to the large industrial scale inkjet nozzles

Schlieren Visualization of Shaping Air During Operation of an Electrostatic Rotary Bell Sprayer: Impact of Shaping Air on Droplet Atomization and Transport

Electrostatic rotary bell sprayers (ERBSs) are widely used in the automotive industry. In ERBS, atomization is facilitated using centrifugal forces which disintegrate the paint film inside the cup into droplets at the cup edge. The droplets are then transported by the flow of a shaping air (SA) and electrostatic forces to a target surface; the characteristics of these droplets dramatically influence the quality of a painted surface and the painting transfer efficiency. In the current paper, a novel Schlieren-based visualization of the shaping air in the absence of paint droplets was performed during a qualitative investigation to delineate shaping air flow behavior and its interaction with droplets and droplet transport. An infrared thermographic flow visualization (IRFV) method and droplet size measurement were used to complement the Schlieren data for providing insight into shaping air-droplet interactions. The results demonstrated the impact of different operating conditions on the SA flow pattern, and the influence SA has on the secondary atomization and transport of droplets. Hence, these experimental methods combine with a useful tool for optimizing SA configurations that improve spray quality, droplet transport, and the efficiency of ERBS operations

A NUMERICAL STUDY OF A NEW SPRAY APPLICATOR

This study focuses on the design and development of a new spray applicator design utilizing effects of imposed pressure oscillations in conjunction with cavitation collapse energy to create distribution of fine droplets. An oscillating horn placed inside the nozzle performing high frequency oscillations is envisioned to provide the necessary pressure perturbations on the exiting liquid jet, while the nozzle geometry design in configured to amplify cavitation process. Initially, a two-zone approach modeling the nozzle interior and exterior in a separate fashion and later, a coupled strategy is proposed. Parametric studies describing the effect of horn stroke length, frequency, its position inside the nozzle in combination with different nozzle designs and liquid flow rates are explored to identify their contribution in obtaining desired cavitation characteristics. In this regard, incorporation of a backward facing step profile within the nozzle shows strong capability of generating the required cavitation and flow field distribution at the nozzle exit. The velocity modulations occuring at the nozzle exit due to oscillating horn structure result in a wide gamut of liquid structures specific to the imposed oscillation frequency and modulation amplitude. The disintegration characteristics of these modulated liquid jets are studied using a Volume-of-Fluid (VOF) interface capturing approach based on finite volume methodology employing an interface compression scheme. VOF methods are validated against experimental results and then subsequently used to study scaling parameters governing the modulated liquid jets. To perform coupled interior-exterior nozzle computations with cavitation, two new cavitation models are presented: First, a model based on Homogeneous Equilibrium assumptions for tracking cavitation events in a compressible framework is presented. Owing to its inability to simulate incompressible cavitating flows, a new cavitation event tracking model based on a Cavitation-Induced-Momentum-Defect (CIMD) correction approach is formulated utilizing a scalar transport model for vapor volume fraction with relevant transport, diffusion and source terms. Validations of both the models against experimental observations are detailed. Coupled internal-external liquid flow computations from the proposed atomizer design using a VOF-CIMD strategy shows strong potential for rapid drop formation in the presence of cavitation effects. A prototype model of a new spray applicator design is presented