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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Droplet breakup by multimodal nonlinear Rayleigh Taylor instability

A droplet impacted by a shock wave will undergo a process of fragmentation due to the development of interfacial hydrodynamic instabilities. The interface experiences variable acceleration and shear that result in the development of both inertial (Rayleigh–Taylor) and shear (Kelvin–Helmholtz) instabilities. These perturbations grow in time and drive the fragmentation and breakup of the deformed droplet. Experiments are performed on nominally 0.86 mm water droplet subjected to a Mach 7.6 detonation wave, resulting in a high Weber number (~36,000) breakup event. Perturbation growth is measured from a series of high-speed (> MHz) shadowgraph images. It is proposed that, given the size of the large-scale perturbations observed in experiments, these instabilities are growing in the non-linear regime and can be described by bubble-merger models for nonlinear mixing. Calculations are performed for the growth rates and size of these instabilities using deformation and external flow models to establish the time-dependent boundary conditions. The concurrence of the measured perturbation widths and the predictions of the simple model lend credence to the theory. This novel approach serves to open a new avenue in the characterization of droplet breakup via hydrodynamic instabilities.

Droplet breakup↗
DOE OSTI2023

Euler–Lagrange stochastic modeling of droplet breakup and impact in supersonic flight

Blunt bodied aircraft traveling supersonically in weather environments may be damaged by impacts with water droplets and other airborne particles, such as snow and ice. Prior to an impact, these particles will encounter a bow shock that causes a discontinuity in their relative velocity with the gas phase, which can lead droplets to breakup into smaller droplets. These smaller droplets are more easily diverted from colliding with the blunt body due to their significantly reduced inertia relative to the initial rain droplets. One-way coupled Euler–Lagrange simulations are used to study the dynamics of droplets approaching a blunt body in steady two dimensional and axi-symmetric flow fields using a stochastic version of the Taylor analogy breakup model for the breakup dynamics. Ultimately, the dominant mechanism determining engineering quantities of interest was observed to be a competition between breakup time and the time available for a droplet to reach the body after encountering the bow shock. At Mach numbers 2, 3, and 6, the competition between these mechanisms was the dominant factor determining the momentum transfer to the blunt body via droplet collisions, which can be well characterized by a scaling relation.

Briney, Sam (ORCID:0000000179061081)↗
DOE OSTI2025

Stokes-dependent droplet collection efficiency on a NACA 0012 airfoil from droplet-informed simulations with statistical overloading

Accurate modelling of ice accretion on aircraft wings requires analysing droplet impingement on the surface to optimize the design of ice-protection systems. We perform Euler–Lagrange simulations of a droplet-laden flow impinging on a NACA 0012 airfoil. Our study includes water droplets with eight discrete sizes ranging from 1 to 160 microns. We vary the free-stream velocity of the incoming airflow in the range 60 ≤ U ≤ 240 m s −1 and the chord length of the airfoil in the range 0.5 ≤ c ≤ 2 m. Due to the dilute nature of supercooled clouds, one-way coupling is used in the simulations. The effects of droplet breakup and collision are also neglected. To reduce the computational cost, we employ statistical overloading of droplets, allowing us to simulate millions of impinging droplets in a time span on the order of milliseconds. Our results show that the droplet collection efficiency, which measures the likelihood of droplet impingement on the airfoil surface, increases with droplet size and free-stream velocity but decreases with airfoil size. We demonstrate that collection efficiency, impingement velocity and impingement angle are primarily dictated by a single non-dimensional parameter, the droplet Stokes number. We also identify a critical stagnation-streamline Stokes number below which impingements do not occur and use it to estimate the minimum droplet size for impingement. In addition, we observe droplet behaviour to become Stokes number independent at large values of the Stokes number. This article is part of the theme issue ‘Heat and mass transfer in frost and ice’.

Science & Technology - Other Topics↗
DOE OSTI2022

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↗
DOE OSTI2023

Evolution of titanium particle combustion in potassium perchlorate and air

Understanding titanium particle combustion processes is critical not only for characterizing existing pyrotechnic systems but also for creating new igniter designs. In order to characterize titanium particle combustion processes, morphologies, and temperatures, simultaneous spatially-resolved electric field holography and imaging pyrometry techniques were used to capture post-ignition data at up to 7 kHz. Due to the phase and thermal distortions present in the combustion cloud, traditional digital in-line holography techniques fail to capture accurate data. Here in this work, electric field holography techniques are used in order to cancel distortions and capture the three-dimensional spatial locations and diameters of the particles. In order to estimate the projected surface temperatures of the titanium particles, an imaging pyrometry method that ratios emission at 750 and 850 nm is utilized. Using these diagnostics, joint statistics are collected for particle size, morphology, velocity, and temperature. Results show that, early in the combustion process, the titanium particles are primarily oxidized by potassium perchlorate inside the igniter cup, resulting in projected surface temperatures near 3000 K. Later in the process, the particles interact with ambient air, resulting in lower surface temperatures around 2400 K and the formation of flame zones. These results are consistent with adiabatic flame temperature predictions as well as particle morphology observations of a titanium core with a TiO 2 surface. Late stage particle expansion, star fragmentation, and molten droplet breakup events are also observed using the time-resolved morphology and temperature diagnostics. These results illustrate the different stages of titanium particle combustion in pyrotechnic environments, which can be used to inform improvements in next-generation igniters.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

High-speed imaging of transition from fluid breakup to phase explosion in electric explosion of tungsten wires in air

High-speed visible imaging of sub-microsecond electric explosion of wires at the low specific energy deposition threshold reveals three distinct modes of wire failure as capacitor charge voltage and energy deposition are increased. For 100 micron diameter gold-plated tungsten wires of 2 cm length, deposited energies of 1.9 eV/atom produces a liquid column that undergoes hydrodynamic breakup into droplets with radii of order of wire diameter on timescales of 200 μs. Instability growth, column breakup, and droplet coalescence follow classic Rayleigh-Plateau predictions for instability of viscous fluid column. Above 3.2 eV/atom of deposited energy, wires are seen to abruptly transition to an expanding mixture of micron scale liquid-droplets and vapor within one frame (less than 3.33 μs), which has been termed ‘phase explosion’ in literature. Between these two limits, at 2.5 eV/atom of deposited energy, wire radius is unchanged for the first 10 μs before the onset of a rapid expansion and disintegration that resembles homogenous nucleation of mechanically unstable bubbles. Here, thermodynamic calculations are presented that separate cases by temperature obtained during heating: below boiling point, near boiling point, and exceeding boiling point.

42 ENGINEERING↗
DOE OSTI2020

A combined numerical and experimental study to elucidate primary breakup dynamics in liquid metal droplet-on-demand printing

Droplet-on-demand liquid metal jetting is emerging as a powerful technology for the additive manufacturing of metallic parts. The success of this method hinges on overcoming several technological challenges. Additionally, the principal one among these challenges is the controlled repeatable ejection of single uniform droplets. Due to the high density and surface tension of liquid metals, the droplet ejection process occurs near the minimal extremes of the printability phase diagram, defined by acceptable ranges for the Weber (We) and Ohnesorge (Oh) numbers. In this work, we experimentally demonstrate the satellite-free ejection of pneumatically actuated molten tin droplets in this extreme corner of printability and use a combination of high-speed video analysis and volume-of-fluid modeling to elucidate the droplet dynamics. While the simulations at low Oh and We can correctly describe several aspects of the breakup process, such as an increasing tail and pinch-point near the nozzle, no single parameter set can completely capture the droplet shape at breakup. Instead, the experimental droplet dynamics appear to include features from both high and low Oh breakup. This disagreement is ascribed to the incomplete description of the droplet ejection process including wetting and exit effects near the nozzle opening and surface effects such as transient cooling and oxide formation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Characterization of Oxy-Coal Swirl Injector

The article presents the design and testing of a coal-slurry swirl-pintle injector for high pressure oxy-coal combustion systems. Pressurized oxy-coal combustion-based systems have the potential to improve efficiency by recovering latent heat of the steam in flue gas and achieve 90% CO2 capture. In oxy-coal combustion, coal is burned in the presence of pure oxygen, which results in higher efficiency and less greenhouse gas in the exhaust. With the advancement of pressurized oxy-coal combustor research, there is a need to investigate injector technology suitable for this unique combustion approach. Effective atomization and mixing of coal-slurry and oxidizer pose a challenge for the efficient burning of coal particles. A swirl-pintle type injector was designed and tested to enhance the atomization of the coal-water slurry spray by adding a swirl to the oxygen flow path. Although pintle type injectors are traditionally used in rocket engines, they present a promising approach in clean coal combustion technology due to higher mixing effectiveness and enhanced performance. The mixing behavior of three pintle injectors with different swirl numbers (S = 0, 0.9, and 1.2) was tested using a high-speed shadow sizing technique. Mixture ratios of 30% (by mass) coal-water slurry were studied. The droplet diameter and dispersion characteristics were determined from shadow images of coal-water spray. The jet breakup length, droplet number, total moment ratio (TMR), and Ohnesorge number were then calculated to compare the performance of different injectors. The paper presents an empirical correlation of the TMR with droplet size and spray regimes. For a pintle injector with S = 1.2 swirler, the droplets diameter was found to be in the range of 1 mm to 12 mm. The jet breakup length was also shorter in comparison to S= 0 and 0.9 injectors. A second atomization zone was also observed at 2 and 5 diameters downstream of injector exist at spray edge and jet core respectively

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

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↗
DOE OSTI2021

Machine learning accelerated turbulence modeling of transient flashing jets

We report modeling the sudden depressurization of superheated liquids through nozzles is a challenge because the pressure drop causes rapid flash boiling of the liquid. The resulting jet usually demonstrates a wide range of structures, including ligaments and droplets, due to both mechanical and thermodynamic effects. As the simulation comprises increasingly numerous phenomena, the computational cost begins to increase. One way to moderate the additional cost is to use machine learning surrogacy for specific elements of the calculation. This study presents a machine learning-assisted computational fluid dynamics approach for simulating the atomization of flashing liquids accounting for distinct stages, from primary atomization to secondary breakup to small droplets using the Σ - Y model coupled with the homogeneous relaxation model. Notably, the models for thermodynamic non-equilibrium (HRM) and Σ - Y are coupled, for the first time, with a deep neural network that simulates the turbulence quantities, which are then used in the prediction of superheated liquid jet atomization. The data-driven component of this method is used for turbulence modeling, avoiding the solution of the two-equation turbulence model typically used for Reynolds-averaged Navier-Stokes simulations for these problems. Both the accuracy and speed of the hybrid approach are evaluated, demonstrating adequate accuracy and at least 25% faster computational fluid dynamics simulations than the traditional approach. This acceleration suggests that perhaps additional components of the calculation could be replaced for even further benefit. Published under an exclusive license by AIP Publishing.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

An Efficient Bayesian Approach to Learning Droplet Collision Kernels: Proof of Concept Using “Cloudy,” a New n -Moment Bulk Microphysics Scheme

The small-scale microphysical processes governing the formation of precipitation particles cannot be resolved explicitly by cloud resolving and climate models. Instead, they are represented by microphysics schemes that are based on a combination of theoretical knowledge, statistical assumptions, and fitting to data (“tuning”). Historically, tuning was done in an ad hoc fashion, leading to parameter choices that are not explainable or repeatable. Recent work has treated it as an inverse problem that can be solved by Bayesian inference. The posterior distribution of the parameters given the data—the solution of Bayesian inference—is found through computationally expensive sampling methods, which require over $\mathcal{O}$(10 5 ) evaluations of the forward model; this is prohibitive for many models. We present a proof of concept of Bayesian learning applied to a new bulk microphysics scheme named “Cloudy,” using the recently developed Calibrate-Emulate-Sample (CES) algorithm. Cloudy models collision-coalescence and collisional breakup of cloud droplets with an adjustable number of prognostic moments and with easily modifiable assumptions for the cloud droplet mass distribution and the collision kernel. The CES algorithm uses machine learning tools to accelerate Bayesian inference by reducing the number of forward evaluations needed to $\mathcal{O}$(10 2 ). It also exhibits a smoothing effect when forward evaluations are polluted by noise. In a suite of perfect-model experiments, we show that CES enables computationally efficient Bayesian inference of parameters in Cloudy from noisy observations of moments of the droplet mass distribution. In an additional imperfect-model experiment, a collision kernel parameter is successfully learned from output generated by a Lagrangian particle-based microphysics model.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Large-eddy simulation of non-vaporizing sprays using the spectral-element method

Predictive simulations of high-pressure sprays require accurate representation of the turbulent gaseous flow field generated by liquid jet. Typically, the accuracy that can be obtained with low-order numerical methods (e.g. finite volume, finite element) is limited by stability issues in fine grids and the order of convergence of the method. In this work, we resolve the turbulent flow field in an Eulerian manner using the high-order spectral element method, coupled with a Lagrangian parcels approach to model the atomizing liquid jet. Large eddy simulations of single-hole sprays under non-evaporative conditions were conducted and compared against experimental data from Margot et al. (2008) and Spray A data from the Engine Combustion Network. The sensitivity of liquid penetration and droplet sizes to different breakup model parameters was studied. The effect of different numerical parameters, such as polynomial order of the solution (grid resolution), on liquid penetration was also analyzed. The method achieved grid-independent results using p-refinement, achieving finer resolution (by a factor of x 1.7 - x 3.5) in the gas-phase solution than in state-of-the-art simulations using the finite-volume method. Here the results showed good agreement with experimental data, demonstrating the ability of the current method to accurately capture liquid penetration and the shape of the spray.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Breakups are complicated: an efficient representation of collisional breakup in the superdroplet method

Abstract. A key constraint of particle-based methods for modeling cloud microphysics is the conservation of total particle number, which is required for computational tractability. The process of collisional breakup poses a particular challenge to this framework, as breakup events often produce many droplet fragments of varying sizes, which would require creating new particles in the system. This work introduces a representation of collisional breakup in the so-called “superdroplet” method which conserves the total number of superdroplets in the system. This representation extends an existing stochastic collisional-coalescence scheme and samples from a fragment size distribution in an additional Monte Carlo step. This method is demonstrated in a set of idealized box model and single-column warm-rain simulations. We further discuss the effects of the breakup dynamic and fragment size distribution on the particle size distribution, hydrometeor population, and microphysical process rates. Box model experiments serve to characterize the impacts of properties such as coalescence efficiency and fragmentation function on the relative roles of collisional breakup and coalescence. The results demonstrate that this representation of collisional breakup can produce a stationary particle size distribution, in which breakup and coalescence rates are approximately equal, and that it recovers expected behavior such as a reduction in precipitate-sized particles in the column model. The breakup algorithm presented here contributes to an open-source pythonic implementation of the superdroplet method, PySDM, which will facilitate future research using particle-based microphysics.

de Jong, Emily (ORCID:0000000253104554)↗
DOE OSTI2023

A physics-driven Σ-Y atomization model for heavy-duty engine simulations

The atomization of a liquid jet is a multi-scale and multi-physics problem of interest for many engineering applications. Particularly, it drives the fuel-oxidizer mixing and dictates the efficiency of combustion engines. High-fidelity multi-phase simulations remain challenging due to the excessive computational cost required to capture all the atomization scales. Thus, atomization models are necessary to represent sub-grid liquid structures. Here, in this work, a modified Σ-Y model in the context of Eulerian-Lagrangian Spray Atomization (ELSA) is used to transport the surface area density of the spray. The model's predictive performance is assessed under various operating conditions relevant to heavy-duty engines using the Engine Combustion Network (ECN) Spray C and Spray D research-grade injectors. The classic droplet collision formulation of the Σ-Y model alone does not replicate the response of the measured spray surface area to changes in injector, ambient pressure, and injection pressure, requiring individual tuning of the model's parameters. Instead, a transition between dense and dilute spray breakup mechanisms is proposed in terms of the average droplet spacing. The collision breakup mechanism represents the dilute spray, whereas the droplet size in the dense spray is driven by a competition between the integral scale of turbulence and the balance between the turbulent kinetic energy and the surface energy of the droplets. Such an approach minimizes the requirements for model tuning. Moreover, the role of the constants of a compressible standard k-ε RANS model is assessed in the injector's internal flow and external spray simulation framework, and an updated set is proposed. The results are validated against x-ray radiography and Ultra-Small Angle X-ray Scattering (USAXS) data and highlight the predictive capabilities of the proposed physics-driven Σ-Y model, which is compatible with engine simulation turnaround times.

42 ENGINEERING↗
DOE OSTI2021

High-speed phase contrast imaging of spray breakup of jet fuels under combusting conditions

X-ray phase contrast imaging is conducted at 90,517 Hz on a fuel spray to characterize the breakup of the bulk fuel into ligaments and individual droplets in a single-sector, swirl-stabilized combustor under reacting conditions. Phase contrast imaging is used to qualitatively assess spray breakup for two fuels: Jet-A, which represents a normal viscosity fuel, and a blend of JP-5 (64%) and farnesane (36% by volume), which represents a high-viscosity fuel, at three fuel-flow rates and two air inlet temperatures. Time-series images of the fuels show that atomization occurs much more rapidly at higher fuel pressure with thinner ligaments being rapidly shredded. The high-viscosity fuel is qualitatively observed to have markedly longer, thicker ligaments and larger droplet diameters after the primary breakup than the normal viscosity fuel. Using an image processing and droplet quantification strategy, the mean droplet velocity magnitudes were found to decrease with decreasing fuel pressure and fuel-flow rate. The increase in preheat temperature from 323 to 370 K results in an increase in the mean droplet velocity magnitude and a decrease in numerical average and Sauter mean diameter, indicating improved atomization. The high-viscosity fuel was found to have larger average droplet diameters at each condition than the normal viscosity fuel. The increased preheat is found to enhance the combustion efficiency, which is hypothesized to couple with the improved atomization due to the higher combustion temperatures. This indicates the importance of examining spray atomization and breakup under realistic combusting conditions for relevant fuels as the heat release directly couples with the atomization process.

42 ENGINEERING↗
DOE OSTI2025

Revealing mechanisms of processing defect mitigation in laser powder bed fusion via shaped beams using high-speed X-ray imaging

The laser powder bed fusion (LPBF) process utilizing a focused Gaussian-shaped beam faces challenges, including pore formation, melt pool fluctuation and liquid spattering. While beam shaping technology has been explored as a potential approach for defect mitigation, the beam-matter interaction dynamics during melting with shaped beams remain unclear. Here, we report the direct observation of ring-shaped beam-matter interaction dynamics, including pore formation, melt pool fluctuation and liquid spattering, and unveil defect mitigation mechanisms in ring-shaped beam laser powder bed fusion process. Here, we find that, by spatially manipulating incident laser rays, the ring-shaped beam controls keyhole morphology, thereby managing the distribution of the reflected rays. This manipulation can effectively eliminate the formation of an unstable cavity at the keyhole tip, stabilizing the keyhole and mitigating keyhole pores. This enhanced keyhole stability effectively reduces the melt pool fluctuation, the formation of liquid breakup induced spatters and liquid droplet colliding induced large spatters in the laser powder bed fusion process. Additionally, the high-energy forefront of the ring-shaped beam effectively melts the powder bed, reducing agglomeration liquid spatter in the laser powder bed fusion process. The discovered defect mitigation mechanisms may guide the design of beam shaping strategies for simultaneously increasing the quality and productivity of metal additive manufacturing.

Beam shaping↗
DOE OSTI2021

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↗