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This paper aims to demonstrate the capabilities of a diffuse interface free energy lattice Boltzmann method to perform direct numerical simulations of liquid–liquid dispersions in a well-controlled turbulent environment. The goal of this research study is to develop numerical techniques that can visualize and quantify drop interaction with the turbulent vortices. The obtained information will be used for the development of sub-models of drop breakup for multi-scale simulations.

A pure binary liquid system is considered that is subject to fully developed statistically stationary turbulent flow field in a cubic fully periodic box with the edge size of 300 lattice units. Three turbulent flow fields with varying energy input are examined and their coherent structures are visualized using a normalized Q-criterion. The evolution of the liquid–liquid interface is tracked as a function of time. The detailed explanation of the numerical method is provided with a highlight on a choice of the numerical parameters.

Drop breakup mechanisms differ depending on energy input. Drops break due to interaction with the vortices. Quantification of turbulent structures shows that the size of vortices increases with the decrease of energy input. Drop interacts simultaneously with multiple vortices of the size comparable to or smaller than the drop size. Vortices of the size smaller than the drop size disturb drop interface and pinch off the satellites. Vortices of the size comparable to the drop size tend to elongate the drop and tear it apart producing daughter drops and satellites. Addition of the second phase enhances turbulent dissipation at the high wavenumbers. To obtain physically realistic two-phase energy spectra, the multiple-relaxation-time collision operator should be used.

Detailed information of drop breakup in the turbulent flow field is crucial for the development of drop breakup sub-models that are necessary for multi-scale numerical simulations. The improvement of numerical methods that can provide these data and produce reliable results is important. This work made one step towards a better understanding of how drops interact with the turbulent vortices.

This paper aims to summarize the latest developments both in terms of theoretical understanding and experimental techniques related to inkjet fluids. The purpose is to provide practitioners a self-contained review of how the performance of inkjet and inkjet-based three-dimensional (3D) printing is fundamentally influenced by the properties of inkjet fluids.

This paper is written for practitioners who may not be familiar with the underlying physics of inkjet printing. The paper thus begins with a brief review of basic concepts in inkjet fluid characterization and the relevant dimensionless groups. Then, how drop impact and contact angle affect the footprint and resolution of inkjet printing is reviewed, especially onto powder and fabrics that are relevant to 3D printing and flexible electronics applications. A future outlook is given at the end of this review paper.

The jettability of Newtonian fluids is well-studied and has been generalized using a dimensionless Ohnesorge number. However, the inclusion of various functional materials may modify the ink fluid properties, leading to non-Newtonian behavior, such as shear thinning and elasticity. This paper discusses the current understanding of common inkjet fluids, such as particle suspensions, shear-thinning fluids and viscoelastic fluids.

A number of excellent review papers on the applications of inkjet and inkjet-based 3D printing already exist. This paper focuses on highlighting the current scientific understanding and possible future directions.

The numerical simulation of dispersed-phase evolution in injection molding process of polymer blends is of great significance in both adjusting material microstructure and improving performances of the final products. This paper aims to present a numerical strategy for the simulation of dispersed-phase evolution for immiscible polymer blends in injection molding.

First, the dispersed-phase modeling is discussed in detail. Then the Maffettone–Minale model, affine deformation model, breakup model and coalescence statistical model are chosen for the dispersed-phase evolution. A general coupled model of microscopic morphological evolution and macroscopic flow field is constructed. Besides, a stable finite element simulation strategy based on pressure-stabilizing/Petrov–Galerkin/streamline-upwind/Petrov–Galerkin method is adopted for both scales.

Finally, the simulation results are compared and evaluated with the experimental data, suggesting the reliability of the presented numerical strategy.

The coupled modeling of dispersed-phase and complex flow field during injection molding and the tracing and simulation of droplet evolution during the whole process can be achieved.

The purpose of this study is to investigate structure parameters that influence the mixing process of droplets-gas in underwater depth-adjustable launcher cooling chamber and help engineers who design the launcher to distinguish the most important factor that impacts mixing performance in the cooling chamber.

Euler–Lagrangian droplet tracking method was used to simulate droplets-gas mixing process in the cooling chamber. The SST k-w model was adopted to simulate turbulence. Droplet breakup was described by KHRT hybrid model using modified contains which are more fit to the supersonic main flow condition.

The results show the counter-rotating vortex pairs which caused by injected liquid accelerate the mixing process. High-pressure supersonic freestream makes the liquid jet break into more small droplets due to the high momentum of the main stream. Axial injection angle has the greatest influence on Sauter mean diameter (SMD). Penetration height, SMD and total pressure loss slightly change in different tangential injection conditions. However, mixedness decreases with reduction of tangential injection angle due to a more limited space for spray developing. Enlarging orifice diameter raises penetration and mixedness greatly, while SMD and total pressure loss increase slightly.

The findings of this study confirm the key structure parameter to improve mixing performance in the cooling chamber. Engineers who design the underwater depth-adjustable launcher can refer the findings in this study to make control of launching power more accurate.

The purpose of this study is to perform a detailed review on the numerical modeling of multiphase and multicomponent flows in microfluidic system using phase-field method. The phase-field method is of emerging importance in numerical computation of transport phenomena involving multiple phases and/or components. This method is not only used to model interfacial phenomena typical to multiphase flows encountered in engineering and nature but also turns out to be a promising tool in modeling the dynamics of complex fluid-fluid interfaces encountered in physiological systems such as dynamics of vesicles and red blood cells). Intrinsically, a priori unknown topological evolution of interfaces offers to be the most concerning challenge toward accurate modeling of moving boundary problems. However, the numerical difficulties can be tackled simultaneously with numerical convenience and thermodynamic rigor in the paradigm of the phase field method.

The phase-field method replaces the macroscopically sharp interfaces separating the fluids by a diffuse transition layer where the interfacial forces are smoothly distributed. As against the moving mesh methods (Lagrangian) for the explicit tracking of interfaces, the phase-field method implicitly captures the same through the evolution of a phase-field function (Eulerian). In contrast to the deployment of an artificially smoothing function for the interface as used in the volume of a fluid or level set method, however, the phase-field method uses mixing free energy for describing the interface. This needs the consideration of an additional equation for an order parameter. The dynamic evolution of the system (equation for order parameter) can be described by Allen–Cahn or Cahn–Hilliard formulation, which couples with the Navier–Stokes equation with the aid of a forcing function that depends on the chemical potential and the gradient of the order parameter.

In this review, first, the authors discuss the broad motivation and the fundamental theoretical foundation associated with phase-field modeling from the perspective of computational microfluidics. They subsequently pinpoint the outstanding numerical challenges, including estimations of the model-free parameters. They outline some numerical examples, including electrohydrodynamic flows, to demonstrate the efficacy of the method. Finally, they pinpoint various emerging issues and futuristic perspectives connecting the phase-field method and computational microfluidics.

This paper gives unique perspectives to future directions of research on this topic.

A numerical study of heat transfer enhancement due to the deformation of droplets at high Reynolds numbers is described. The two phase‐flow has been computed with a 3D DNS program using the volume‐of‐fluid method. The droplets are deformed because of the surrounding gas stream especially due to a sudden rise of flow velocity from zero to U_i. As the governing non‐dimensional parameter the Weber number of the droplets has been varied between 1.3 and 10.8 by assuming different surface tensions at Reynolds numbers between 360 and 853. The dynamical behavior of the droplets as a function of the Weber and the Ohnsorge number are in good agreement with experimental results from the literature. At the highest Reynolds number Re=853, a significant dependency of Nu on We has been found. The comparison of a Nusselt number computed with the real surface area with a Nusselt number computed with the spherical surface area shows that the heat transfer increases not only due to the droplet motion but also due to the larger surface area of the deformed droplet.

Subcooled flow boiling phenomenon is characterized by coolant phase change in the vicinity of the heated wall. Although coolant phase change from liquid to vapour phase significantly enhances the heat transfer coefficient due to latent heat of vaporization, eventually the formed vapor bubbles may coalesce and deteriorate the heat transfer from the heated wall to the liquid phase. Due to the poor heat transfer characteristics of the vapour phase, the heat transfer rate drastically reduces when it reaches a specific value of wall heat flux. Such a threshold value is identified as critical heat flux (CHF), and the phenomenon is known as departure from nucleate boiling (DNB). An accurate prediction of CHF and its location is critical to the safe operation of nuclear reactors. Therefore, the present study aims at the prediction of DNB type CHF in a hexagonal sub-assembly.

Computational fluid dynamics (CFD) simulations are performed to predict DNB in a hexagonal sub-assembly. The methodology uses an Eulerian–Eulerian multiphase flow (EEMF) model in conjunction with multiple size group (MuSiG) model. The breakup and coalescence of vapour bubbles are accounted using a population balance approach.

Bubble departure diameter parameters in EEMF framework are recalibrated to simulate the near atmospheric pressure conditions. The predictions from the modified correlation for bubble departure diameter are found to be in good agreement against the experimental data. The simulations are further extended to investigate the influence of blockage (b) on DNB type CHF at low operating pressure conditions. Larger size vapour bubbles are observed to move away from the corner sub-channel region due to the presence of blockage. Corner sub-channels were found to be more prone to experience DNB type CHF compared to the interior and edge sub-channels.

An accurate prediction of CHF and its location is critical to the safe operation of nuclear reactors. Moreover, a wide spectrum of heat transfer equipment of engineering interest will be benefited by an accurate prediction of wall characteristics using breakup and coalescence-based models as described in the present study.

Simulations are performed to predict DNB type CHF. The EEMF and wall heat flux partition model framework coupled with the MuSiG model is novel, and a detailed variation of the coolant velocity, temperature and vapour volume fraction in a hexagonal sub-assembly was obtained. The present CFD model framework was observed to predict the onset of vapour volume fraction and DNB type CHF. Simulations are further extended to predict CHF in a hexagonal sub-assembly under the influence of blockage. For all the values of blockage, the vapour volume fraction is found to be higher in the corner region, and thus the corner sub-channel experiences CHF. Although DNB type CHF is observed in corner sub-channel, it is noticed that the presence of blockage in the interior sub-channel promotes the coolant mixing and results in higher values of CHF in the corner sub-channel.

The reaction dynamics of combustible clouds at high temperatures and pressures are a common form of energy output in aerospace and explosion accidents. The cloud explosion process is often affected by the external initial conditions. This study aims to numerically study the effects of airflow velocity, initial temperature and fuel concentration on the explosion behavior of isopropyl nitrate/air mixture in a semiconstrained combustor.

The discrete-phase model was adopted to consider the interaction between the gas-phase and droplet particles. A wave model was applied to the droplet breakup. A finite rate/eddy dissipation model was used to simulate the explosion process of the fuel cloud.

The peak pressure and temperature growth rate both decrease with the increasing initial temperature (1,000–2,200 K) of the combustor at a lower airflow velocity. The peak pressure increases with the increase of airflow velocity (50–100 m/s), whereas the peak temperature is not sensitive to the initial high temperature. The peak pressure of the two-phase explosion decreases with concentration (200–1,500 g/m³), whereas the peak temperature first increases and then decreases as the concentration increases.

Chain explosion reactions often occur under high-temperature, high-pressure and turbulent conditions. This study aims to provide prevention and data support for a gas–liquid two-phase explosion.

Sustained turbulence is realized by continuously injecting air and liquid fuel into a semiconfined high-temperature and high-pressure combustor to obtain the reaction dynamic parameters of a two-phase explosion.

The purpose of this paper is to develop a high‐throughput approach to optimize printing of pigment‐based formulations.

A total of 40 formulations were robotically prepared by varying the concentrations of diethyleneglycol, glycerol and surfynol. In addition, a variety of inkjet printer (process) variables (voltage, pulse width and frequency) was varied. The combined influence of these two sets of variables on printing performance were determined, analysed and optimised using the Statistical Software Package (MODDE 8), which uses multiple linear regression and partial least square analysis.

The components diethyleneglycol and surfynol were observed to predominantly control viscosity and surface tension of all formulations, which voltage and pulse width were found to be the main factors controlling the spread of the droplet on the substrate.

Optimisation of pigment‐based formulations has typically involved the one‐by‐one systematic variation of components in a stepwise manner. The work reported here allowed the generation of a robust model allowing the properties of any new formulation to be accurately predicted. Importantly, the experimental tools and methods developed can be applied quite generally to the preparation of any new formulation for inkjet printing application.

Experimental design and high‐throughput technology allow new formulations to be accurately predicted for diverse inkjet applications.

The purpose of this study is to investigate the effects of the shear-thinning viscoelastic behavior of the surrounding matrix on droplet deformation by weakly compressible smoothed particle hydrodynamics (WC-SPH). Also, the effect of the presence of another droplet is examined.

A modified consistent weakly compressible SPH method is proposed. After code verification, a complete parameter study is performed for a drop under the simple shear flow of a Giesekus liquid. The investigated parameters are 0.048≤Ca ≤ 14.4, 0.1≤c ≤ 10, 0.04≤De ≤ 10, 0≤α ≤ 1 and 0.12≤Re ≤ 12.

It is demonstrated that the rheological behavior of the surrounding fluid could dramatically affect the droplet deformation. It is shown that the droplet deformation is increased by increasing Re and Ca. In contrast, the droplet deformation is decreased by increasing a, De and polymer content. Also, it is indicated the presence of another droplet could drastically affect the flow field, and the primary stress difference (N1) is resonated between two droplets.

The main originality of this paper is to introduce a new consistent WC-SPH algorithm. The proposed method is very versatile for tackling the shear-thinning viscoelastic multiphase problems. Furthermore, a complete parameter study is performed for a drop under the simple shear flow of Giesekus liquid. Another novelty of the current paper is studying the effect of the presence of a second droplet. To the best of the authors’ knowledge, this is performed for the first time.