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Results for “non-newtonian fluids”

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 OSTI2026

Filament extension atomizers: A study of integration potential into spray dryers for high-viscosity and non-Newtonian fluids

Filament extension atomizers (FEAs) are an emerging class of spray nozzles designed to atomize high-viscosity and non-Newtonian fluids that are challenging for conventional pressure or two-fluid nozzles. In this study, we investigate the influence of roller geometry, surface velocity, roller material, and fluid rheology on the atomization performance of FEA systems using concentrated whey protein suspensions (50–70 wt. %). Extensional and shear rheology experiments, along with high-speed imaging and particle image velocimetry, reveal that filament breakup dynamics are governed by competition between inertial, capillary, and viscoelastic stresses. High roller rotational velocity leads to narrower spray cones, contradicting rheology experiments and suggests a significant inertial contribution to filament breakup. Smaller rollers operating at the same rotational velocity led to broader spray cones consistent with expectations. An FEA nozzle was integrated into a conventional dryer producing particles in the 100 μm range. Results suggest that FEA technology enables atomization of highly viscous fluids at industrially relevant spray cone angles similar to those generated by pressure nozzles, offering a pathway to improve energy efficiency in spray drying by enabling higher solids loading feedstocks. Furthermore, these insights provide critical guidance for optimizing FEA nozzle designs and process parameters across a range of applications.

Energy efficiency↗
DOE OSTI2025

3D polycatenated architected materials

Architected materials derive their properties from the geometric arrangement of their internal structural elements. Their designs rely on continuous networks of members to control the global mechanical behavior of the bulk. Here, in this study, we introduce a class of materials that consist of discrete concatenated rings or cage particles interlocked in three-dimensional networks, forming polycatenated architected materials (PAMs). We propose a general design framework that translates arbitrary crystalline networks into particle concatenations and geometries. In response to small external loads, PAMs behave like non-Newtonian fluids, showing both shear-thinning and shear-thickening responses, which can be controlled by their catenation topologies. At larger strains, PAMs behave like lattices and foams, with a nonlinear stress-strain relation. At microscale, we demonstrate that PAMs can change their shapes in response to applied electrostatic charges. The distinctive properties of PAMs pave the path for developing stimuli-responsive materials, energy-absorbing systems, and morphing architectures.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Filament Extension Atomization for High Solids Loading in Energy Efficient Spray Drying Systems

We demonstrate that we could scale FEA to reach outputs needed by industrial production, while increasing solids loading of the sprayed product by at least 30% and maintaining equal or better spray powder. After testing a wide range of products, in collaboration with industry partners we decided on our primary spray products of dry whey and WPC-80, two common materials processed and sold by US manufacturers with different parameters. We sprayed these with FEA at solids loadings of 70% for dry whey and 45% for WPC-80 with a spray output with particle sizes similar to industrial particles sizes and reduced variation in particle size. We simultaneously scaled up FEA first with a multi-nip with 6 nips surrounding a central roller with parallel axis of rotation and eventually with a tapered design that solved problems we encountered with our initial design. We were able to achieve output from a single array from our first design of up to 4.7 liters per minute (L/min) and from an array of our second multi-nip of 8 L/min exceeding expectations. This demonstrates that FEA technology can indeed be scaled up to meet the needs of industrial production. More arrays can be added as necessary to meet a wide range of spray dryer designs. We also tested FEA to create dried powders from a small scale (10 L/hour of water removal) spray dryer. Though we were not able to produce large quantities of powder from FEA due to challenges in integration, the powder we produced was higher quality and produced from higher solids loading materials. From our technoeconomic analysis we for a typically sized spray dryer, we estimate a 27% cost reduction and 41% energy and carbon reduction for WPC-80 and a 39-57% cost reduction and 52-76% energy reduction for sweet dry whey (depending on the exact product).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Flow-Driven Stretch Fluctuations Govern the Nonlinear Viscoelasticity of Elongating Associative Polymer Networks

We use nonequilibrium molecular dynamics simulations to verify recent tube-model predictions that associative polymer networks exhibit broad stretch fluctuations during elongational flow. Simulations further show that these fluctuating dynamics give rise to the rate-dependent extensional viscosity 𝜂 𝐸 measured in filament stretching experiments on H-bonding networks. Simulations model bivalent associative networks with a reactive bead-spring model for varying association strength and extensional strain rate. We observe that stretch fluctuations are driven by a new form of chain tumbling, where chains continually collapse and elongate as their associations break and reform within the advecting network. This produces a broad, nearly uniform distribution of chain stretch over a wide range of strain rates, manifesting as a rate-independent plateau in the extensional stress. Our results show that the nonlinear viscoelasticity of associative networks is dominated by large fluctuations in molecular response, which cannot be captured by current mean-field models.

biomimetic & bio-inspired materials↗
DOE OSTI2026

Insights into mixing of non-isothermal multi-polymer melts for complex plastics recycling

Catalytic recycling or upcycling of plastics is often limited not by catalyst performance, but by transport, arising from highly viscous, non-Newtonian polymer melts. In this work, we develop a reactor-scale framework that integrates rheological measurements, constitutive modeling, computational fluid dynamics (CFD), and experiments to quantify mixing, heat transfer, and dispersion in surrogate hydrocarbon melts representing mixed plastics systems. Temperature- and shear rate-dependent viscosity of low-density polyethylene (LDPE) and high-density polyethylene (HDPE) is measured to create two surrogate polymers (PLD and PHD) that capture the dominant shear-thinning flow behavior while neglecting strong elastic effects, enabling tractable simulation of non-isothermal, polymer-melt mixing using a Carreau-Arrhenius generalized Newtonian framework. Three-dimensional CFD simulations are employed to evaluate impeller performance in PLD using mixing time, cavern volume, thermal uniformity, and interfacial area for regimes in which viscoelastic effects are not dominant. We show that magnetic stir bars commonly used in lab-scale studies produce large thermal gradients (~60 °C) and poor mixing, even under idealized power delivery and polymer flow conditions. In contrast, close-clearance anchor impellers achieve near-isothermal operation, reduce mixing times by up to 5×, and provide >90% active circulation volume. We further demonstrate that, at low pseudo-Deborah number (De*), motor power requirements can be predicted directly from shear rate-dependent rheology using the Carreau-Arrhenius framework, enabling rational selection of operating conditions. Extension to surrogate immiscible multi-polymer systems based on PLD and PHD shows that interfacial area is highly sensitive to operating conditions and impeller design, with coaxial anchor-turbine configurations enhancing dispersion by up to 4 × .

Close-clearance impellers↗