We investigate the evaporation of a droplet surrounded by superheated vapor with relative motion between phases. The evaporating droplet is a challenging process, as one must take into account the transport of mass, momentum, and heat. Here a lattice Boltzmann method is employed where phase change is controlled by a nonideal equation of state. First, numerical simulations are compared to the D-2 law for a vaporizing static droplet and good agreement is observed. Results are then presented for a droplet in a Lagrangian frame under a superheated vapor flow. Evaporation is described in terms of the temperature difference between liquid-vapor and the inertial forces. The internal liquid circulation driven by surface-shear stresses due to convection enhances the evaporation rate. Numerical simulations demonstrate that for higher Reynolds numbers, the dynamics of vaporization flux can be significantly affected, which may cause an oscillatory behavior on the droplet evaporation. The droplet-wake interaction and local mass flux are discussed in detail.
Purpose - In welding there is an intricate coupling between the composition of the material and the shape and depth of the weld pool. In certain materials, the weld pool may not penetrate the material easily, so that it is difficult or impossible to weld, while other seemingly quite similar materials may be well suited for welding. This is due to the convective heat transfer in the melt where the flow is driven primarily by surface tension gradients. This paper aims to study how surface active agents affect the flow and thus the welding properties by surveying some recent 3D simulations of weld pools. Design/methodology/approach - Some basic concepts in the modelling of flow in a weld pool are reviewed. The mathematical models for a convecting melt, with a detailed model for the surface tension and the Marangoni stress in the presence of surfactants, are presented. The effect of the sign of the Marangoni coefficient on the flow pattern, and thus, via melting and freezing, on the shape of the weld pool, is discussed. Findings - It is seen that it is beneficial to have surfactants present at the pool surface, in order to have good penetration. Results from a refined surface tension model that accounts for non-equilibrium redistribution of surfactants are presented. It is seen that the surfactant concentration is significantly modified by the fluid flow. Thereby, the effective surface tension and the Marangoni stresses are altered, and the redistribution of surfactants will affect the penetration depth of the weld pool. Originality/value - The importance of surfactants for weld pool shapes, and in particular the convective redistribution of surfactants, is clarified.
This paper introduces and experimentally verifies a method for robust, active control of friction reduction in microchannels, enabling new flow control applications and overcoming previous limitations with regard to sustainable liquid pressure. The air pockets trapped at a
superhydrophobic micrograting during liquid priming are coupled to an actively controlled pressure source, allowing the pressure difference over the air/liquid interface to be dynamically adjusted. This allows for manipulating the friction reduction properties of the surface, enabling active control of liquid mass flow through the channel. It also permits for sustainable air lubrication at theoretically unlimited liquid pressures, without loss of superhydrophobic properties. With the non-optimized grating used in the experiment, a difference in liquid mass flow of 4.8 % is obtained by alternatively collapsing and recreating the air pockets using the coupled pressure source, which is in line with a FE analysis of the same geometry. A FE analysis of a more optimized geometry predicts a mass flow change of over 30%, which would make possible new microfluidic devices based on local friction control. It is also experimentally shown that our method allows for sustainable liquid pressure 3 times higher than the Laplace pressure of a passive device.
In this article, we present a modelling approach for rapid dynamic wetting based on the phase field theory. We show that in order to model this accurately, it is important to allow for a non-equilibrium wetting boundary condition. Using a condition of this type, we obtain a direct match with experimental results reported in the literature for rapid spreading of liquid droplets on dry surfaces. By extracting the dissipation of energy and the rate of change of kinetic energy in the flow simulation, we identify a new wetting regime during the rapid phase of spreading. This is characterized by the main dissipation to be due to a re-organization of molecules at the contact line, in a diffusive or active process. This regime serves as an addition to the other wetting regimes that have previously been reported in the literature.
In the present paper we present a phenomenological description of droplet dynamics in a bifurcating channel that is based on three-dimensional numerical experiments using the Phase Field theory. Droplet dynamics is investigated in a junction, which has symmetric outflow conditions in its daughter branches. We identify two different flow regimes as the droplets interact with the tip of the bifurcation, splitting and non-splitting. A distinct criterion for the flow regime transition is found based on the initial droplet volume and the Capillary (Ca) number. The Rayleigh Plateau instability is identified as a driving mechanism for the droplet breakup close to the threshold between the splitting and non-splitting regime.
In this paper we present simulations of dynamic wetting far from equilibrium based on phase field theory. In direct simulations of recent experiments [J. C. Bird, S. Mandre, and H. A. Stone, Phys. Rev. Lett. 100, 234501 (2008)], we show that in order to correctly capture the dynamics of rapid wetting, it is crucial to account for nonequilibrium at the contact line, where the gas, liquid, and solid meet. A term in the boundary condition at the solid surface that naturally arises in the phase field theory is interpreted as allowing for the establishment of a local structure in the immediate vicinity of the contact line. A direct qualitative and quantitative match with experimental data of spontaneously wetting liquid droplets is shown.
It is well recognized that the fluid flow is an important factor in overall heat and mass transfer in molten pools during arc welding, affecting geometry of the pool and temperature distribution in the pool and in the HAZ. These in turn influence solification behavior, which determine the mechanical properties and quality of the weld fusion zone. Here, a comprehensive numerical model of the time dependent weld pool flow in GTA welding, with a moving heat source has been developed. This model included heat transfer, radiation, evaporation, electromagnetic forces and Marangoni stress in the free surface boundary. With this 3D, fully time dependent model, the true chaotic time dependent melt flow is obtained. The time dependent properties of flow velocities and temperature of numerical results are examined. It shows that the temperature fields axe strongly affected by convection at the weld pool surfaces. The fluid flow in the weld pool is highly complex and it influences the weld pool's depth and width. Moreover, the velocity field at the surface of the specimen determines the streamlines defining the traveling paths of inclusions such as slag particles.
The fluid flows in molten pools during arc welding are important factors. These in turn influence in overall heat and mass transfer, which determine the mechanical properties and quality of the weld fusion zone. Here, modelling results are presented concerning the time dependent weld pool flow and temperature in gas tungsten arc welding (GTA) of the difference type of stainless steels. It is proved that the temperature fields are strongly affected by the convection at the weld pool’s surfaces. With the stainless steel type 304 (low sulfur content 0.0005 weight % and high sulfur content 0.0139 weight %), the actual chaotic time dependent melt flow is obtained with a fully time dependent model. In those cases, the fluid flow in the weld pool is highly complex and it influenced the weld pool`s depth and width. For the 645 SMO steel, which has an extremely low sulfur content and low conductivity, the chaotic fluid flows did not appear. The calculated geometry of the weld fusion zone and heat affected zone were in good agreement with the experimental results, both with or without chaotic fluid flows.
The impact of a solid object on a free liquid surface is quite complex. This problem has challenged researchers for centuries and remains of interest today. Recently Duez et al. [1] published experimental results on the splash when a solid sphere enters a liquid Surprisingly, a small change in the surface chemistry of the object can turn a big splash into an inconspicuous disappearance and vice versa. We study this problem by solving the Navier-Stokes together with the Cahn-Hilliard equations, [2, 3], which allows us to simulate the motion of a free air-water surface in detail, in the presence of surface tension and dynamic wetting. Quantitative computational modeling of dynamic wetting is difficult in itself, but here the use of this tool allows us to study in detail how the wetting properties determine whether a splash appears or not. Our simulated results are compared with the experiments of Duez et al.
This paper presents a model, using a phase-field method, that is able to simulate the motion of a solid sphere impacting on a liquid surface, including the effects of capillary and hydrodynamic forces. The basic phenomena that were the subject of our research effort are the small scale mechanism such as the wetting property of the solid surface which control the large scale phenomena of the interaction. The coupled problem during the impact will be formulated by the inclusion of the surface energies of the solid surface in the formulation, which gives a reliable prediction of the motion of solid objects in/on/out of a liquid surface and the hydrodynamic behaviours at small scales when the inertia of fluid is less important than its surface tension. Numerical results at different surface wettabilities and impact conditions will be presented and compared with the experiments of Duez el al. [C. Duez, C. Ybert, C. Clanet, L. Bocquet, Nat. Phys. 3 (2007) 180-183] and Lee and Kim [D. Lee. H. Kim, Langmuir 24 (1) (2008) 142]. (C) 2009 IMACS. Published by Elsevier B.V. All rights reserved.
In this paper we simulate the evolution and free particle motion of an individual nucleus that grows into a dendritic crystal. The melt flow and the convective heat transfer around the crystal are simulated as they settle due to gravity. There is an intricate coupling between the settling and the evolution of the crystal. The relative flow induced by the settling enhances the growth at the downward facing parts, which in its turn affects the subsequent settling motion. Simulations have been done in two dimensions using a semi-sharp phase-field model. The flow was constrained to a rigid body motion by using Lagrange multipliers inside the solidified part. The model was formulated using two different meshes. One is a fixed background mesh, which covers the whole domain. The other is an adaptive mesh, where the node points are also translated and rotated with the movement of the solid particle. In the latter, the dendritic growth is simulated by the semi-sharp phase-field method.
The impact of a solid sphere on a liquid surface has challenged researchers for centuries and remains of interest today. Recently, Duez [Nat. Phys. 3, 180 (2007)] published experimental results of the splash generated when a solid sphere enters water. Interestingly, the microscopic properties of the solid surface control the nature of the macroscopic behavior of the splash. So by a change in the surface chemistry of the solid sphere, a big splash can be turned into an inconspicuous disappearance and vice versa. This problem was investigated by numerical simulations based on the Navier-Stokes equations coupled with the Cahn-Hilliard equations. This system allows us to simulate the motion of an air-water interface as a solid sphere impacts the liquid pond. The inclusion of the surface energies of the solid surface in the formulation gives a reasonably quantitative description of the dynamic wetting. Numerical results with different wetting properties and impact speed are presented and directly compared with the recent experimental results from Duez.
The dynamical behavior of almost neutrally buoyant finite-size rigid fibers or rods in turbulent channel flow is studied by direct numerical simulations. The time evolution of the fiber orientation and translational and rotational motions in a statistically steady channel flow is obtained for three different fiber lengths. The turbulent flow is modeled by an entropy lattice Boltzmann method, and the interaction between fibers and carrier fluid is modeled through an external boundary force method. Direct contact and lubrication force models for fiber-fiber interactions and fiber-wall interaction are taken into account to allow for a full four-way interaction. The density ratio is chosen to mimic cellulose fibers in water. It is shown that the finite size leads to fiber-turbulence interactions that are significantly different from earlier reported results for point like particles (e.g., elongated ellipsoids smaller than the Kolmogorov scale). An effect that becomes increasingly accentuated with fiber length is an accumulation in high-speed regions near the wall, resulting in a mean fiber velocity that is higher than the mean fluid velocity. The simulation results indicate that the finite-size fibers tend to stay in the high-speed streaks due to collisions with the wall. In the central region of the channel, long fibers tend to align in the spanwise direction. Closer to the wall the long fibers instead tend to toward to a rotation in the shear plane, while very close to the wall they become predominantly aligned in the streamwise direction.
A comprehensive three-dimensional, time-dependent model of heat, momentum and solute transfer during solidification is carried out to illustrate the influence of weak convection, caused by surface tension forces, on radial dopant segregation occurring in crystal growth under micro-gravity conditions. 3D adaptive finite element method is used in order to simulate the motion and deformation of the solidification interface. The geometry studied is a Bridgman configuration with a partly coated surface. The small slots in the coating gives a free surface in a controlled way, and is varied in order to alter the Marangoni flow. In this study, A comparison is made between the numerical results and the experimental results. A good agreement has been observed for the effective distribution coefficient keff and for the radial segregation [Delta]c’. The radial dopant segregation is affected by weak convection.
This paper presents a comprehensive three-dimensional, time-dependent model for simulating the adsorption kinetics and the redistribution of surfactants at the surface and in the bulk of a weld pool. A physicochemical approach that was included in this paper allows the surfactant concentration at the surface and in the bulk to depart from its thermodynamical equilibrium. The Langmuir equilibrium adsorption ratio was based on the k(seg) coefficient of Sahoo (1988, "Surface-Tension of Binary Metal-Surface-Active Solute Systems Under Conditions Relevant to Welding Metallurgy," Metall. Trans. B, 19B, pp. 483-491) and was finally used for calculating fluid flow and heat transfer in gas tungsten arc welding of a super duplex stainless steel, SAF 2507. In this study, the authors applied the multicomponent surfactant mass transfer model to investigate the effect of the influence of sulfur and oxygen redistribution in welding of a super duplex stainless steel.
Inkjet technology has been recognized as one of the most successful and promising micro-system technologies. The wide application areas of printer heads and the increasing demand of high quality prints are making ink consumption and print see-through important topics in the inkjet technology. In the present study we investigate numerically the impact of ink droplets onto a porous material that mimics the paper structure. The mathematical framework is based on a free energy formulation, coupling the Cahn-Hilliard and Navier Stokes equations, for the modelling of the two-phase flow. The case studied here consists of a multiphase flow of air-liquid along with the interaction between a solid structure and an interface. In order to characterize the multiphase flow characteristics, we investigate the effects of surface tension and surface wettability on the penetration depth and spreading into the paper-like structure.
This paper presents a technology for dispensing droplets through thin liquid layers. The system consists of a free liquid film, which is suspended in a frame and positioned in front of a piezoelectric printhead. A droplet, generated by the printhead, merges with the film, but due to its momentum, passes through and forms a droplet that separates on the other side and continues its flight. The technology allows the dispensing, mixing and ejecting of picolitre liquid samples in a single step. This paper overviews the concept, potential applications, experiments, results and a numerical model. The experimental work includes studying the flight of ink droplets, which ejected from an inkjet print head, fly through a free ink film, suspended in a frame and positioned in front of the printhead. We experimentally observed that the minimum velocity required for the 80 pl droplets to fly through the 75 ± 24 lm thick ink film was of 6.6 m s-1. We also present a numerical simulation of the passage of liquid droplets through a liquid film. The numerical results for different initial speeds of droplets and their shapes are taken into account. We observed that during the droplet-film interaction, the surface energy is partially converted to kinetic energy, and this, together with the impact time, helps the droplets penetrate the film. The model includes the Navier- Stokes equations with continuum-surface-tension force derived from the phase-field/Cahn-Hilliard equation. This system allows us to simulate the motion of a free surface in the presence of surface tension during merging, mixing and ejection of droplets. The influence of dispensing conditions was studied and it was found that the residual velocity of droplets after their passage through the thin liquid film well matches the measured velocity from the experiment.
We simulate numerically a novel method for dispensing, mixing and ejecting of picolitre liquid samples in a single step. The system consists of a free liquid film, suspended in a frame and positioned in front of a droplet dispenser. On impact, a picolitre droplet merges with the film, but due to its momentum, passes through and forms a droplet that separates on the other side and continues its flight. Through this process the liquid in the droplet and that in the film is mixed in a controlled way. We model the flow using the Navier Stokes together with the Cahn-Hilliard equations. This system allows us to simulate the motion of a free surface in the presence of surface tension during merging, mixing and ejection of droplets. The influence of dispensing conditions was studied and it was found that the residual velocity of droplets after passage through the thin liquid film matches the measured velocity from the experiment well.
Some materials-related microstructural problems calculated using the phase-field method are presented. It is well known that the phase field method requires mesh resolution of a diffuse interface. This makes the use of mesh adaptivity essential especially for fast evolving interfaces and other transient problems. Complex problems in 3D are also computationally challenging so that parallel computations are considered necessary. In this paper, a parallel adaptive finite element scheme is proposed. The scheme keeps the level of node and edge for 2D and level of node and face for 3D instead of the complete history of refinements to facilitate derefinement. The information is local and exchange of information is minimized and also less memory is used. The parallel adaptive algorithms that run on distributed memory machines are implemented in the numerical simulation of dendritic growth and capillary-driven flows.
An existing phase-fieldmodel of two immiscible fluids with a single soluble surfactant present is discussed in detail. We analyze the well-posedness of the model and provide strong evidence that it is mathematically ill-posed for a large set of physically relevant parameters. As a consequence, critical modifications to the model are suggested that substantially increase the domain of validity. Carefully designed numerical simulations offer informative demonstrations as to the sharpness of our theoretical results and the qualities of the physical model. A fully coupled hydrodynamic test-case demonstrates the potential to capture also non-trivial effects on the overall flow.
Since the mechanical properties and the integrity of the weld metal depend on the solidification behaviour and the resulting microstructural characteristics, understanding weld pool solidification is of importance to engineers and scientists. Thermal and fluid flow conditions affect the weld pool geometry and solidification parameters. During solidification of the weld pool, a columnar grain structure develops in the weld metal. Prediction of the formation of the microstructure during welding may be an important and supporting factor for technology optimization. Nowadays, increasing computing power allows direct simulations of the dendritic and cell morphology of columnar grains in the molten zone for specific temperature conditions. In this study, the solidification microstructures of the weld pool at different locations along the fusion boundary are simulated during gas tungsten arc welding of Al-3wt% Cu alloy using the phase-field model for the directional solidification of dilute binary alloys. A macroscopic heat transfer and fluid flow model was developed to assess the solidification parameters, notably the temperature gradient and solidification growth rate. The effect of the welding speed is investigated. Computer simulations of the solidification conditions and the formation of a cellular morphology during the directional solidification in gas tungsten arc welding are described. Moreover, the simulation results are compared with existing theoretical models and experimental findings.
We present a modeling approach that enables numerical simulations of a boiling Van der Waals fluid based on the diffuse interface description. A boundary condition is implemented that allows in and out flux of mass at constant external pressure. In addition, a boundary condition for controlled wetting properties of the boiling surface is also proposed. We present isothermal verification cases for each element of our modeling approach. By using these two boundary conditions we are able to numerically access a system that contains the essential physics of the boiling process at microscopic scales. Evolution of bubbles under film boiling and nucleate boiling conditions are observed by varying boiling surface wettability. We observe flow patters around the three-phase contact line where the phase change is greatest. For a hydrophilic boiling surface, a complex flow pattern consistent with vapor recoil theory is observed.
In this paper, we numerically study particle formation in the rapid expansion of supercritical solution (RESS) process in a two dimensional, axisymmetric geometry, for a benzoic acid + CO2 system. The fluid is described by the classical Navier-Stokes equation, with the thermodynamic pressure being replaced by a generalized pressure tensor. Homogenous particle nucleation, transport, condensation and coagulation are described by a general dynamic equation, which is solved using the method of moments. The results show that the maximal nucleation rate and number density occurs near the nozzle exit, and particle precipitation inside the nozzle might not be ignored. Particles grow mainly across the shocks. Fluid in the shear layer of the jet shows a relatively low temperature, high nucleation rate, and carries particles with small sizes. On the plate, particles within the jet have smaller average size and higher geometric mean, while particles outside the jet shows a larger average size and a lower geometric mean. Increasing the preexpansion temperature will increase both the average particle size and standard deviation. The preexpansion pressure does not show a monotonic dependency with the average particle size. Increasing the distance between the plate and the nozzle exit might decrease the particle size. For all the cases in this paper, the average particle size on the plate is on the order of tens of nanometers.
Axisymmetric rapid expansion of supercritical carbon dioxide is investigated in this article. The extended generalized Bender equation of state is used to give a good description of the fluids over a wide range of pressure and temperature conditions. The locations of Mach disks are analyzed and compared with an experimental correlation for the case where there is no plate positioned in front of the nozzle exit. It is found that the disagreement between our numerical results and the experimental formula is very small when the pressure ratio is small, and increases as the pressure ratio increases. It is also found that with different equations of state, the predicted positions of Mach disks do not differ a lot, but the temperature profiles in the chamber differ a lot. The case where there is a plate positioned in front of the nozzle exit is also studied in this article. A universal similarity solution is obtained.
We numerically study the thermohydrodynamics of boiling for a CO2 + ethanol mixture on lyophilic and lyophobic surfaces in both closed and open systems, based on a diffuse interface model for a two-component system. The corresponding wetting boundary conditions for an isothermal system are proposed and verified in this paper. New phenomena due to the addition of another component, mainly the preferential evaporation of the more volatile component, are observed. In the open system and the closed system, the physical process shows very different characteristics. In the open system, except for the movement of the contact line, the qualitative features are rather similar for lyophobic and lyophilic surfaces. In the closed system, the vortices that are observed on a lyophobic surface are not seen on a lyophilic surface. More sophisticated wetting boundary conditions for nonisothermal, two-component systems might need to be further developed, taking into account the variations of density, temperature, and surface tension near the wall, while numerical results show that the boundary conditions proposed here also work well even in boiling, where the temperature is nonuniform.
The use of supercritical carbon dioxide (scCO(2)) as an apolar solvent has been known for decades. It offers a greener approach than, e.g., hexane or chloroform, when such solvents are needed. The use of scCO(2) in microsystems, however, has only recently started to attract attention. In microfluidics, the flow characteristics need to be known to be able to successfully design such components and systems. As supercritical fluids exhibit the exciting combination of low viscosity, high density, and high diffusion rates, the fluidic behavior is not directly transferrable from aqueous systems. In this paper, three flow regimes in the scCO(2)-liquid water two-phase microfluidic system have been mapped. The effect of both total flow rate and relative flow rate on the flow regime is evaluated. Furthermore, the droplet dynamics at the bifurcating exit channel are analyzed at different flow rates. Due to the low viscosity of scCO(2), segmented flows were observed even at fairly high flow rates. Furthermore, the carbon dioxide droplet behavior exhibited a clear dependence on both flow rate and droplet length.
The initial rapid wetting of a solid surface by a liquid phase is an important step in many industrial processes. Liquid-phase sintering of powder metallurgical steels is one such industrial process, where metallic powders of micrometer size are used. Investigating the dynamic wetting of a high-temperature metallic drop of micrometer size experimentally is very challenging. Here, a phase-field-based numerical model is first implemented and verified by accurately capturing the initial dynamic wetting of millimeter-sized metal drops and then the model is extended to predict the dynamic wetting of a micrometer-sized metal drop. We found, in accordance with recent observations, that contact line friction is required for accurate simulation of dynamic wetting. Our results predict the wetting time for a micrometer-sized metal drop and also indicate that the dynamic wetting patterns at the micro- and millimeter length scales are qualitatively similar. We also found that the wetting process is much faster for a micrometer-sized metal drop compared to a millimeter-sized metal drop.
Liquid wetting of a surface is omnipresent in nature and the advance of micro-fabrication and assembly techniques in recent years offers increasing ability to control this phenomenon. Here, we identify how surface roughness influences the initial dynamic spreading of a partially wetting droplet by studying the spreading on a solid substrate patterned with microstructures just a few micrometers in size. We reveal that the roughness influence can be quantified in terms of a line friction coefficient for the energy dissipation rate at the contact line, and that this can be described in a simple formula in terms of the geometrical parameters of the roughness and the line-friction coefficient of the planar surface. We further identify a criterion to predict if the spreading will be controlled by this surface roughness or by liquid inertia. Our results point to the possibility of selectively controlling the wetting behavior by engineering the surface structure.
We conduct numerical experiments on spreading of viscoelastic droplets on a flat surface. Our work considers a Giesekus fluid characterized by a shear-thinning viscosity and an Oldroyd-B fluid, which is close to a Boger fluid with constant viscosity. Our results qualitatively agree with experimental observations in that both shear thinning and elasticity enhances contact line motion, and that the contact line motion of the Boger fluid obeys the Tanner-Voinov-Hoffman relation. Excluding inertia, the spreading speed shows strong dependence on rheological properties, such as the viscosity ratio between the solvent and the polymer suspension, and the polymeric relaxation time. We also discuss how elasticity can affect contact line motion. The molecular migration theory proposed in the literature is not able to explain the agreement between our simulations and experimental results.