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At least 37 records · Page 2

Volatile propellant droplet evaporation measurements in metered dose inhaler sprays

Many aerosol products rely on the rapid vaporization of volatile propellants to produce a fine spray. In the simplest case, these are binary mixtures of propellant and a delivered product which undergo a flash-evaporation process leaving only the less volatile product in the resultant droplet. In more complex applications, such as pressurized metered-dose inhalers, the non-propellant component may contain dissolved or suspended drug which precipitates or dries to form a matured particle. The size and morphology of the particles depend strongly on the time-history of the droplet as the propellant evaporates. However, measuring the dynamic evaporation processes that occur in dense sprays containing millions of droplets is challenging. In this paper, we demonstrate a novel application of Ultra Small Angle X-ray Scattering to measure the bulk composition of volatile HFC134a–ethanol sprays and compare the obtained results with simple evaporation models in a dry nitrogen environment. The data reveal that diffusion-limiting processes inside the droplet are equally important as external convection and mixing-limited factors in determining evaporative timescales.

42 ENGINEERING↗

Effects of detailed geometry and real fluid thermodynamics on Spray G atomization

We present recent results toward the quantification of spray characteristics at engine conditions for an eight-hole counter-bored (stepped) GDI injector-Spray G in the ECN denomination. This computational study is characterized by two novel features: the detailed description of a real injector's internal surfaces via tomographic reconstruction; and a general equation of state that represents the thermodynamic properties of homogeneous liquid-vapor mixtures. The combined level-set moment-of-fluid approach, coupled to an embedded boundary formulation for moving solid walls, makes it possible to seamlessly connect the injector's internal flow to the spray. The Large Eddy Simulation (LES) discussed here presents evidence of partial hydraulic flipping and, during the closing transient, string cavitation. Results are validated by measurements of spray density profiles and droplet size distribution.

42 ENGINEERING↗

Optimization of spray breakup model parameters for predicting fuel spray and film characteristics in gasoline direct injection engines

This study investigated the behavior of gasoline direct injection (GDI) sprays using computational fluid dynamics (CFD). The authors developed an approach to identify optimal spray breakup model parameters by evaluating an error function across numerous simulations, with the goal of minimizing discrepancies from experimental data. Using the optimal setup, the simulated spray matched well with projected liquid volume distributions, liquid penetration, and spray width measured in a constant-pressure continuous-flow chamber. To further validate the approach, the same setup was tested across various fuels, injectors, and operating conditions. Subsequently, the optimal setup, along with a recently developed spray-wall interaction model, were applied to a direct-injection spark-ignited engine under late-injection conditions to predict and evaluate fuel film formation and evolution at varying engine coolant temperatures. Here, with the centrally mounted injector directing the spray toward the piston, simulations indicated that the spray tends to impinge on the piston surface. The proposed simulation framework also accurately captured the aggregate film area on the piston surface, aligning with previously published experimental results. Moreover, simulations showed that increasing the coolant temperature from cold start conditions (333 K) to warm conditions (363 K) reduced the fuel mass deposited on the piston by roughly 50%. Furthermore, for the spray-guided engine configuration studied in this work, the CFD model predicted minimal film deposition on the spark plug electrodes regardless of the coolant temperatures due to a relatively weak in-cylinder flow during the compression phase.

Computational fluid dynamics (CFD)↗

Geometrical effects on the measured neutron residual stress in additively manufactured cold spray AA6061

Aluminum cold spray additive builds were made with varying wall widths and geometries to explore the effects of build geometry on residual stress development in the additively sprayed material. Deposition rates of over 750 g/hr were achieved without any cracking or delamination of the additively manufactured components. Neutron residual stress measurements revealed a maximum tensile residual stress of 41 MPa at the interface of the substrate and a maximum compressive residual stress of −35 MPa in the cold sprayed material. While there was not found to be significant residual stress changes between the cold sprayed walls, the cold sprayed cylinder had varying residual stress throughout the diameter with the outer diameter having a higher tensile residual stress than the interior. The low residual stress and minimal geometrical dependency demonstrate further part size is possible without concerns for component failure in AA6061. The application of common coating residual stress models to full scale additive builds is evaluated and discussed. The lack of residual stress evolution was studied by in-situ coating property measurement that revealed that the deposition stress of the AA6061 sprays reduced with increased layer thickness. In conclusion, this study provides insight into the evolution of residual stress in cold spray additive components and how both the mechanics and material responses differ from coatings.

Additive manufacturing↗

Support of Adhesion Mechanisms in Al 2 O 3 Aerosol Deposition Through Laser-Induced Particle Impact Testing

Aerosol deposition (AD) is a kinetic spray process capable of depositing ceramic coatings at room temperature, but AD process development is generally a laborious exploration of a large process parameter space. Here, this paper presents a case study investigating whether laser-induced particle impact testing (LIPIT) could be applied to expedite development of an alumina (Al 2 O 3 ) coating on nickel (Ni): Specifically, whether LIPIT measurements could predict critical velocities of adhesion on Ni and Al 2 O 3 , and the effect of ball milling the Al 2 O 3 powder. Because LIPIT has a diffraction-limited lower bound on imageable particle size, the usefulness of Al 2 O 3 powder agglomerates as a proxy for single particles was additionally studied. Overall, LIPIT measurements and AD sprays agreed that ball milling dramatically improves adhesion. Additionally, LIPIT measurements of critical velocity of adhesion of Al 2 O 3 powder agglomerates on Ni and Al 2 O 3 substrates (150 meters per second [m/s] and 250 m/s, respectively) quantitatively agreed with predictions from a previously published model based on picoindentation and molecular dynamics simulations. Together, these findings support the established hypothesis that Al 2 O 3 adheres via a dislocation-mediated mechanism in AD, that Al 2 O 3 powder agglomerates adhere as individual constituent particles rather than collectively, and that, for this case study, LIPIT measurements were predictive of AD process parameters.

Al2O3↗

Combined Experimental/Numerical Study of the Soot Formation Process in a Gasoline Direct-Injection Spray in the Presence of Laser-Induced Plasma Ignition

Here, combustion issued from an eight-hole, direct-injection spray was experimentally studied in a constant-volume pre-burn combustion vessel using simultaneous high-speed diffused back-illumination extinction imaging (DBIEI) and OH* chemiluminescence. DBIEI has been employed to observe the liquid-phase of the spray and to quantitatively investigate the soot formation and oxidation taking place during combustion. The fuel-air mixture was ignited with a plasma induced by a single-shot Nd:YAG laser, permitting precise control of the ignition location in space and time. OH* chemiluminescence was used to track the high-temperature ignition and flame. The study showed that increasing the delay between the end of injection and ignition drastically reduces soot formation without necessarily compromising combustion efficiency. For long delays between the end of injection and ignition (1.9 ms) soot formation was eliminated in the main downstream charge of the fuel spray. However, poorly atomized and large droplets formed at the end of injection (dribble) eventually do form soot near the injector even when none is formed in the main charge. The quantitative soot measurements for these spray and ignition scenarios, resolved in time and space, represents a significant new achievement. Reynolds-averaged Navier-Stokes (RANS) simulations were performed to assess spray mixing and combustion. An analysis of the predicted fuel-air mixture in key regions, defined based upon experimental observations, was used to explain different flame propagation speeds and soot production tendencies when varying ignition timing. The mixture analysis indicates that soot production can be avoided if the flame propagates into regions where the equivalence ratio (Φ) is already below 2. Reactive RANS simulations have also been performed, but with a poor match against the experiment, as the flame speed and heat-release rate are largely over estimated. This modeling weakness appears related to a very high level of turbulent viscosity predicted for the high-momentum spray in the RANS simulations, which is an important consideration for modeling ignition and flame propagation in mixtures immediately created by the spray.

42 ENGINEERING↗

Measurement of laser absorption in underdense plasmas using near-field imaging of the incident and transmitted beams

Measurements of laser absorption in high-temperature, underdense plasmas produced at the Omega Laser Facility are made using two near-field imaging detectors that diagnose the spatial profile and energy of the port P9 beam before and after it transmits through the plasma. The incident beam is sampled using a partial reflection from a full-aperture, (30 cm-diam) uncoated wedge pickoff located before the target chamber vacuum window and final focus lens assembly. A concave mirror reduces the reflected beam size, allowing it to be recorded directly using a charged-coupled device (CCD) camera. The P9 transmitted beam diagnostic (P9TBD) characterizes the transmitted light by terminating the expanded beam on a semi-transparent diffuser and imaging the illuminated surface using a lens and CCD camera. The P9TBD samples a numerical aperture twice as large as the input beam, allowing the energy of transmitted beams with moderate levels of beam spray to be measured accurately. Calibration shots with no plasma provide a path to infer absorption without absolute photometric calibration of either detector. Lastly, the cross-calibration between the two detectors was measured to remain stable at ±200 ppm, enabling measurements of total beam absorption below 1% with ±0.07% error.

47 OTHER INSTRUMENTATION↗

Empirical prediction of saline water atomization pressure loss and spray phase change using local flow pressure analysis

A pressure analysis technique was developed to obtain spray spatial evaporation profile in a thermal desalination process. The technique can replace temperature-based evaporation measurement methods that are challenged by liquid-phase interference. It also provides an alternative to optical methods with high cost and complexity. Fundamental analysis was developed to determine local humidity ratios from changes in local static and dynamic pressures. The analysis was applied to data obtained from an external mixing air-assist atomizer. An empirical model was developed for the pressure loss in atomization process and was used in the analysis of humidity ratio. The results were used to develop empirical correlations for local humidity ratio in spray mediums using inlet conditions. Utilizing inlet conditions to predict evaporation profiles is an important contribution as it eliminates the need to take local spray measurements. Obtaining local data is often difficult and expensive; Our method and correlation circumvent the need for that. Finally, the correlations presented in this paper apply to saline water sprays with total dissolved salt of 0-10 wt%. The salinity-specific correlations are accurate to within ±10% of experimental data. The individual models were aggregated into a unified correlation for salinities within 0-10 wt%. The unified correlation is accurate to within ±18% of experimental data.

42 ENGINEERING↗

Simulating the optical properties of soot using a stochastic soot model

KL extinction measurements are common in literature concerning soot producing sprays because of their nonintrusiveness. Unfortunately, these measurements often rely on bold assumptions of uniform and monodisperse spherical particles. In this work, a Spray A case is simulated using a highly detailed 3D stochastic soot model and the measured and simulated soot volume fraction are compared. Although the simulated volume fraction magnitude is approximately correct, features are much sharper than in the measured data. Optical models based on particle shape are applied to the simulated soot particles to nd the local optical thickness. The modeled optical thickness aligns with the measured volume fraction much more closely than the simulated volume fraction indicating KL extinction measurements are not simply related to soot volume fraction.

Strickland, Tyler↗

A comprehensive numerical investigation on spray models for Direct-Injection Spark-Ignition engines

Gasoline direct-injection spark-ignition (DISI) engines generate a large portion of their unburned hydrocarbon (UHC) and soot emissions during the cold-start phase. A predictive computational fluid dynamics (CFD) modeling framework can be used to understand the physical processes that characterize fuel spray evolution and fuel-film formation at cold start conditions, which can help to reduce engine-out particulate emissions. This study systematically evaluated spray submodels and developed a set of simulation best practices for physical-numerical submodels with the goal of enabling accurate simulations of liquid spray behavior in a DISI engine. Three comprehensive experimental datasets containing free-spray projected liquid volume (PLV), liquid volume fraction (LVF), and near-field X-ray radiography data were used to validate the simulation results and evaluate the spray submodels. Systematic analysis delved into injected parcel distribution, droplet collision, spray breakup, and evaporation via a detailed assessment of the relevant spray submodels. Moreover, the effects of turbulence models and the initial turbulent flow properties on the liquid spray evolution were examined. Based on extensive calibration efforts, a set of simulation best practices for the free spray was developed and validated against the PLV/LVF data. Simulation results indicated that the uniform distribution for parcel initialization, coupled with appropriate droplet collision submodels, provides an improved spray morphology compared to the cluster distribution. The findings also underscored the importance of calibrating the Kelvin-Helmholtz Rayleigh-Taylor (KH-RT) breakup model constants and droplet heat transfer coefficient scaling factor to achieve favorable agreement regarding measured liquid penetration and spray widths. In conclusion, this study marks a substantial stride towards accurately predicting fuel film evolution and soot formation within DISI engine performance.

ECN Spray G↗

Estimation of Sea Spray Aerosol Surface Area Over the Southern Ocean Using Scattering Measurements

This study focuses on methods to estimate dry marine aerosol surface area (SA) from bulk optical measurements. Aerosol SA is used in many models' ice nucleating particle (INP) parameterizations, as well as influencing particle light scattering, hygroscopic growth, and reactivity, but direct observations are scarce in the Southern Ocean (SO). Two campaigns jointly conducted in austral summer 2018 provided co-located measurements of aerosol SA from particle size distributions and lidar to evaluate SA estimation methods in this region. Mie theory calculations based on measured size distributions were used to test a proposed approximation for dry aerosol SA, which relies on estimating effective scattering efficiency (Q) as a function of Ångström exponent (å). For distributions with dry å < 1, Q = 2 was found to be a good approximation within ±50%, but for distributions with dry å > 1, an assumption of Q = 3 as in some prior studies underestimates dry aerosol SA by a factor of 2 or more. We propose a new relationship between dry å and Q, which can be used for –0.2 < å < 2, and suggest å = 0.8 as the cutoff between primary and secondary marine aerosol-dominated distributions. Application of a published methodology to retrieve dry marine aerosol SA from lidar extinction profiles overestimated aerosol SA by a factor of 3–5 during these campaigns. Using Microtops aerosol optical thickness measurements, we derive alternative lidar conversion parameters from our observations, applicable to marine aerosol over the SO.

54 ENVIRONMENTAL SCIENCES↗

Atmospheric particle abundance and sea salt aerosol observations in the springtime Arctic: a focus on blowing snow and leads

Abstract. Sea salt aerosols play an important role in the radiation budget and atmospheric composition over the Arctic, where the climate is rapidly changing. Previous observational studies have shown that Arctic sea ice leads are an important source of sea salt aerosols, and modeling efforts have also proposed blowing snow sublimation as a source. In this study, size-resolved atmospheric particle number concentrations and chemical composition were measured at the Arctic coastal tundra site of Utqiaġvik, Alaska, during spring (3 April–7 May 2016). Blowing snow conditions were observed during 25 % of the 5-week study period and were overpredicted by a commonly used blowing snow parameterization based solely on wind speed and temperature. Throughout the study, open leads were present locally. During periods when blowing snow was observed, significant increases in the number concentrations of 0.01–0.06 µm particles (factor of 6, on average) and 0.06–0.3 µm particles (67 %, on average) and a significant decrease (82 %, on average) in 1–4 µm particles were observed compared to low wind speed periods. These size distribution changes were likely caused by the generation of ultrafine particles from leads and/or blowing snow, with scavenging of supermicron particles by blowing snow. At elevated wind speeds, both submicron and supermicron sodium and chloride mass concentrations were enhanced, consistent with wind-dependent local sea salt aerosol production. At moderate wind speeds below the threshold for blowing snow as well as during observed blowing snow, individual sea spray aerosol particles were measured. These individual salt particles were enriched in calcium relative to sodium in seawater due to the binding of this divalent cation with organic matter in the sea surface microlayer and subsequent enrichment during seawater bubble bursting. The chemical composition of the surface snowpack also showed contributions from sea spray aerosol deposition. Overall, these results show the contribution of sea spray aerosol production from leads on both aerosols and the surface snowpack. Therefore, if blowing snow sublimation contributed to the observed sea salt aerosol, the snow being sublimated would have been impacted by sea spray aerosol deposition rather than upward brine migration through the snowpack. Sea spray aerosol production from leads is expected to increase, with thinning and fracturing of sea ice in the rapidly warming Arctic.

54 ENVIRONMENTAL SCIENCES↗

Development of a Turbulent Liquid Spray Atomization Model for Diesel Engine Simulations (Final Technical Report)

This project addresses the systematic lack of predictive capabilities by spray models within engine CFD codes. We develop a new modeling approach to predict the breakup of diesel sprays based on recent literature showing that liquid turbulence plays a fundamental role in spray atomization. A new body of quantitative validation data is also developed as a critical element of the project, leveraging the joint capabilities of Georgia Tech’s high-pressure continuous-flow spray chamber and Argonne National Lab’s near-nozzle x-ray diagnostics at the Advanced Photon Source. This project contributes spatially-resolved measurements of drop size distribution within well-characterized diesel injectors, Spray A and D, from the Engine Combustion Network (ECN) to the engine combustion community for the first time. Utilizing this new body of measurements, we validate and demonstrate a new spray model for diesel sprays, termed the KH-Faeth model, that predicts global and local spray characteristic more accurately than the widely adopted and employed KH model. Predicted drop size distributions are seen to predict measured drops sizes both quantitatively and predictively, with accurate response in droplet size distributions over a wide range of ambient density, injection pressure, and injector nozzle size (Spray A and D) without model tuning. The KH-Faeth model can reduce error in the predicted centerline droplet size profile by up to 80% for ECN Spray D simulations when compared to use of the widely employed KH model.

33 ADVANCED PROPULSION SYSTEMS↗

Evaluation of Spray and Combustion Models for Simulating Dilute Combustion in a Direct-Injection Spark-Ignition Engine

Dilute combustion in spark-ignition engines has the potential to improve thermal efficiency by mitigating knock and by reducing throttling and wall heat losses. However, ignition and combustion processes can become unstable for dilute operation due to a lowered laminar flame speed, resulting in excessive cycle-to-cycle variability (CCV) of the combustion process. To compensate for the slower combustion in less reactive mixtures, a modified intake port geometry can be employed to generate a strong tumble flow in the cylinder and elevate turbulence levels around the spark plug, thereby promoting a faster transition to turbulent deflagration. Consequently, optimizing combustion chamber geometry and operating strategy is crucial to maximizing the benefits of using dilute combustion with enhanced in-cylinder turbulence across a wide range of operating conditions. Computational fluid dynamics (CFD) simulations can be utilized for virtual engine optimization tasks, but this would require the models to be truly predictive regarding the impact of changes to the engine design and operational parameters.In this study, multicycle large-eddy simulations (LES) are performed for a direct-injection spark-ignition engine to investigate the model performance in predicting engine combustion characteristics with respect to changes in the intake configuration. A tumble plate that blocks the lower part of the intake port inlet is used to vary the tumble. A set of CFD models that have been recently developed are employed, which takes into account the drag of nonspherical droplets, flash-boiling behavior of liquid sprays, spray-wall interaction, surrogate formulation of a research-grade E10 gasoline, and fast chemical kinetic solvers. Simulation results are compared to experimental engine data in terms of cylinder pressure, apparent heat release rate, mass fraction burned timing, and flame images. It is found that LES employing the state-of-the-art CFD models are capable of properly predicting the spray processes and reproducing the measured mean cylinder pressure for the case with the tumble plate. On the other hand, the LES over-predicts the combustion rate during the early combustion stage and under-estimates the CCV, and these discrepancies become larger when the tumble plate is removed.

computational fluid dynamics simulation↗

Baselining the Indirect Effect by Improving Quantification of Sea Spray and Marine Sources at Ascension Island (Final Report)

Oceans cover two-thirds of the Earth and understanding the interactions of aerosols with clouds in these large marine regions requires quantifying the man-made contributions to the budget of cloud-drop forming particles (known as cloud condensation nuclei, or CCN) relative to the non-manmade “baseline” conditions and understanding the meteorology of boundary layer clouds. Modeling studies have shown substantial uncertainties and sensitivities to natural marine CCN sources, meaning that to reduce uncertainties in indirect effects we must be able to better quantify the CCN budget in ocean regions. While models provide important constraints on these uncertainties, actually reducing uncertainties requires substantial observations in open-ocean and coastal regions in order to establish the baseline on which manmade emissions are added. The tropical South Atlantic Ocean is one of the least-sampled regions of the planet, making the comprehensive measurements of the Department of Energy Atmospheric Radiation Measurement Layered Atlantic Smoke Interactions with Clouds (LASIC) campaign provides the longest record of aerosol size distribution measurements from a differential mobility analyzer in a cloud-influenced marine location in the ARM database, with 17 months of ground-based aerosol size distribution measurements. This project addressed the research topic of Aerosol-Cloud Interactions (ACI) by supporting three publications from the LASIC measurements: 1. The ARM measurements were combined with a new value-added technique that was pioneered by the Russell group for quantifying sea salt. This quantification of sea salt uses supermicron scattering measurements for retrieving reasonable sea spray mass concentrations, providing the best-available, observationally-constrained estimate of the sea spray mode properties when supermicron size distribution measurements are not available. 2. The fitted modes of the distribution were used to investigate the signatures of cloud processing for very clean to very smoky aerosol conditions, revealing not only differences in the particles that activate in clouds but also in the mechanisms that control that droplet formation process. In clean air, the size required to form a cloud droplet is influenced by the number of particles, as well as how quickly particles take up water during growth in cloud. 3. Building on this aerosol characterization, cloud and meteorological conditions were used to evaluate aerosol-related changes in cloud albedo and optical depth. We introduced a new method of decomposing the impact of aerosols on clouds known as the Twomey effect by incorporating retrieved supersaturation from two independent sets of observations to constrain the feedback of aerosol particles on cloud properties. The method quantifies the reduction of the Twomey effect at high aerosol concentrations, which has never been explained quantitatively by observations. In addition, the results provide the first direct validation for the conditions observed in the tropical South Atlantic of a parcel-based approach that is embedded in many climate models. Together these findings illustrate how ARM extended field campaigns in stratocumulus-covered regions can be used to constrain ACI processes with direct observations, providing specific radiative effects without models. By making such process-specific constraints available to improve ACI in global climate models, ARM observations play a key role in supporting model development.

58 GEOSCIENCES↗

Model development for flash boiling spray and validations with isooctane, hexane, ethanol and their binary mixtures

The objective of this study is to develop a comprehensive model for spray atomization under the consideration of flash boiling, which includes nucleation, bubble growth, and droplet breakup. Although flash boiling has been previously studied, there is still no well-established analytical and numerical model of their mechanisms, or general guidelines on the implementation of this atomization strategy. In this study, detailed formulations are elaborated for the unified spray atomization model under both non-flash and flash boiling conditions. Next, the model was implemented into CFD software and 3-D simulations were performed for model validations. Two fuel blends are tested: ethanol-isooctane blends and hexane-isooctane blends. Simulation results were compared with the experimental measurements conducted using two methodologies, DBI (Diffuse Backlight Imaging) system for spray images captured by a high-speed camera, and a PDA (Phase Doppler Anemometry) system for droplet size measurement during the spray injection process. It was found that the current flash boiling model can accurately capture the spray characteristics under different environment conditions, such as the spray plume interactions and liquid penetration. The averaged Sauter mean diameter (SMD) calculations match the measurement sufficiently well. The spray structures for both single- and multi-component fuels during the injection process are well represented by current model.

42 ENGINEERING↗

Experimental study of flash boiling spray with isooctane, hexane, ethanol and their binary mixtures

The main goal of this study is to understand the effect of fuel properties on flash boiling sprays using multi-hole injectors. Macroscopic characteristics were investigated using Diffused Backlight Imaging (DBI) and quantified with liquid penetration length and spray angles. Phase Doppler Anemometry (PDA) was applied to measure the droplet size and velocity. Behaviors of spray with three single-component fuels (isooctane, hexane, ethanol) under different ambient pressures (100 kPa, 80 kPa, 50 kPa, 22 kPa) as well as their binary mixtures under different blend ratios (10%, 30%, 85%) were reported and analyzed. The results showed that adding ethanol or hexane to isooctane could both promote flash boiling by increasing the overall vapor pressure thus superheated degree. Under mixing ratios of 10% and 30%, sprays with ethanol blends showed more severe flash boiling comparing with sprays with hexane blends. Shorter liquid penetration and better liquid dispersion have been observed. Comparing with isooctane spray, the droplet size continuously decreased with increasing hexane content due to enhanced breakup and faster vaporization. Sprays with ethanol mixtures showed a different trend. Noticeable droplet size reduction has been observed for spray with 10% ethanol content. However, droplet size did not further decrease with higher blend ratios regardless of higher flash boiling intensity. Such observations indicate severe vaporization inhibition caused by the high latent heat of vaporization of ethanol. For sprays with all test fuels, collapsing occurred when the pressure ratio of ambient pressure to saturation pressure (Rp) dropped below 0.3.

03 NATURAL GAS↗