Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Droplet coalescence”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Controlling process instability for defect lean metal additive manufacturing

The process instabilities intrinsic to the localized laser-powder bed interaction cause the formation of various defects in laser powder bed fusion (LPBF) additive manufacturing process. Particularly, the stochastic formation of large spatters leads to unpredictable defects in the as-printed parts. Here we report the elimination of large spatters through controlling laser-powder bed interaction instabilities by using nanoparticles. The elimination of large spatters results in 3D printing of defect lean sample with good consistency and enhanced properties. We reveal that two mechanisms work synergistically to eliminate all types of large spatters: (1) nanoparticle-enabled control of molten pool fluctuation eliminates the liquid breakup induced large spatters; (2) nanoparticle-enabled control of the liquid droplet coalescence eliminates liquid droplet colliding induced large spatters. The nanoparticle-enabled simultaneous stabilization of molten pool fluctuation and prevention of liquid droplet coalescence discovered here provide a potential way to achieve defect lean metal additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Are turbulence effects on droplet collision–coalescence a key to understanding observed rain formation in clouds?

Rain formation is a critical factor governing the lifecycle and radiative forcing of clouds and therefore it is a key element of weather and climate. Cloud microphysics–turbulence interactions occur across a wide range of scales and are challenging to represent in atmospheric models with limited resolution. Based on past experiments and idealized numerical simulations, it has been postulated that cloud turbulence accelerates rain formation by enhancing drop collision–coalescence. We provide substantial evidence for significant impacts of turbulence on the evolution of cloud droplet size distributions and rain formation by comparing high-resolution observations of cumulus congestus clouds with state-of-the-art large-eddy simulations coupled with a Lagrangian particle-based microphysics scheme. Turbulent coalescence must be included in the model to accurately represent the observed drop size distributions, especially for drizzle drop sizes at lower heights in the cloud. Turbulence causes earlier rain formation and greater rain accumulation compared to simulations with gravitational coalescence only. The observed rain size distribution tail just above cloud base follows a power law scaling that deviates from theoretical scalings considering either a purely gravitation collision kernel or a turbulent kernel neglecting droplet inertial effects, providing additional evidence for turbulent coalescence in clouds. In contrast, large aerosols acting as cloud condensation nuclei (“giant CCN”) do not significantly impact rain formation owing to their long timescale to reach equilibrium wet size relative to the lifetime of rising cumulus thermals. Overall, turbulent drop coalescence exerts a dominant influence on rain initiation in warm cumulus clouds, with limited impacts of giant CCN.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Chemically sensitive fluorescence imaging of colliding microdroplets

Here, we present a simple optical capability for generating spatially resolved chemical concentration maps of mixing fluids using a chemically sensitive dye, 1-hydroxy-3,6,8-pyrenetrisulfonic acid, detected by planar laser induced fluorescence. To demonstrate an application of this capability, we investigate the collision and mixing of a pair of microdroplets in air. The two microdroplets are composed of different fluids, methanol and water, with the dye initially in the methanol droplet. When the droplets collide and mixing process develops, the fluorescence of the dye shifts from blue to green as the solvent environment changes. A series of spectral-temporal images of the collision and subsequent mixing are recorded, from which we extract the distribution of the two intermixing droplet species reflected in the spatially resolved dye spectra. Images reveal material transfer between droplets in both coalescing and non-coalescing droplet collisions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Enhancing Steam-Side Heat Transfer via Microdroplet Ejection using Inorganic Coatings

During condensation of water on a superhydrophobic nanostructured surfaces, droplets coalesce and jump (droplet ejection) due to the release of excess surface energy. Meticulously designed nanostructured surfaces or coatings capable of droplet ejection can enhance heat transfer performance by easy removal of droplets during condensation. In the present work, the capabilities of the Nelumbo droplet ejection coatings technology currently used in commercial heat exchangers are explored and optimized for materials and conditions relevant to steam condensers. Specifically, this includes (1) adapting and optimizing the procedures and chemistries to deposit droplet ejecting coatings on materials used in the steam condenser, (2) testing of the heat transfer, durability, and fouling of the fabricated coatings under a variety of steam condenser relevant conditions, and (3) modeling of the impact of droplet dynamics and interfacial properties on heat transfer in steam condensers. We experimentally demonstrated that at low supersaturation conditions (S~1.02), developed superhydrophobic nanostructured surface gives a 40% higher peak heat transfer flux and a 17% higher peak overall heat transfer coefficient (U) with droplet ejection mechanism compared to the dropwise condensation mechanism on the same nanostructured surface. Though the experimentally observed droplet ejection mechanism was short-lived (~3 min) due to the limitation of the chiller to maintain a constant supersaturation condition in fabricated steam condenser. And large variations in water inlet temperature (+ to - 2 degrees C) caused flooding of nanostructure (Wenzel state) at higher supersaturation (S > or = 1.12). This is an important finding because typical supersaturation levels in field operation are over 1.8 and as such, either the flooding potential for these materials should be improved or operation at lower supersaturation may be required to maximize heat transfer efficiency. If supersaturation conditions can be maintained reliably in the steam condenser in addition to droplet ejection mechanism during condensation, this could provide a potential 2% reduction in water flow rate which equates to a savings of over 3900 gallons of water per minute for a 500 MW steam turbine and over $0.3MM savings annually given a 0.02 cent marginal water withdrawal cost. It is also worth noting that these savings are based on improvement of droplet ejection coatings over coatings capable of performing consistent dropwise mechanism in in-field surface condensers. Savings due to the droplet ejections coatings when compared to bare substrates could be much higher. Additionally, the present work provides the importance of steam condenser operating conditions and insights into the challenges in modeling the condensing droplet dynamics on surfaces.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

mphys-surrogate-model

This repository contains python scripts for building and studying reduced-order-modeling representations of droplet coalescence for eventual use in atmospheric models. The included data are generated from high-fidelity superdroplet methods and are utilized by machine learning pipelines to build data-driven models of droplet size distributions that evolve under coalescence. This repository further includes scripts to determine prediction (uncertainty) intervals on the data-driven model products based on conformal prediction.

Katona, JonasE [Lawrence Livermore National Labora↗
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 OSTI2024

Patterned Quasi-Liquid Surfaces for Condensation of Low Surface Tension Fluids

Extensive research concerns dropwise condensation of low surface tension fluids to promote energy efficiency and decarbonization in thermal energy systems. However, it is challenging as these fluids typically result in filmwise condensation. Drawing inspiration from the Namib desert beetle that enhances condensation through patterned wettability, conventional beetle-inspired surfaces excel in water condensation but flood when condensing low surface tension fluids. In this work, a patterned quasi-liquid surface is reported that achieves exceptional dropwise condensation of low surface tension fluids. The surface consists of alternating stripes with low surface energy, that is, a perfluoropolyether (PFPE) and fluorinated quasi-liquid surface (FQLS), that shows ultralow contact angle hysteresis for ethanol and hexane. Further, the PFPE stripes are slightly more slippery, acting as slippery bridges that accelerate droplet coalescence and removal. It is experimentally demonstrated that the striped PFPE-FQLS pattern exhibits a heat transfer coefficient 85%, 330%, and 550% higher than that of PFPE, fluorinated silane, and filmwise condensation, respectively. This study reveals that a high contact angle is desired to sustain dropwise condensation, irrespective of contact angle hysteresis. These findings provide a new paradigm for promoting the dropwise condensation of low surface tension fluids and offer valuable insights into surface design for energy sustainability.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Ultrasonic in-situ water-cut measurement using ultrasonic oil-water separation for affecting sound speed calibration

An apparatus and method for the separation of an oil-water mixture into its components are described. An acoustic radiation force moves oil droplets to the nodes of an acoustic standing wave generated in a vertical column containing the oil-water mixture. Once the droplets are sufficiently close together, attractive forces become dominant and the droplets may coalesce to form larger droplets, which have greater buoyancy, and separation of the mixture into a layer of oil and a layer of water occurs, not possible by simple gravitational separation. Acoustically-driven oil-water separation may be used for water-cut measurements in oil production wells, since separation of the oil from the water permits accurate sound speed measurements to be made for both the oil and the water, thereby allowing frequent in situ calibrations of the apparatus to determine whether sound speed measurements on the mixture are accurate in the event that one or both of the mixture constituents is changing.

02 PETROLEUM↗
DOE OSTI2020

High Speed In-situ X-ray Imaging of 3D Freeze Printing of Aerogels

3D freeze printing (3DFP) combines drop-on-demand (DOD) inkjet printing with freeze casting to fabricate lightweight and multifunctional aerogels with customized geometries. Freeze casting is an efficient and easily implemented method capable of fabricating porous, sponge-like structures for many different applications. This process enables tailoring the microstructure of the final product (i.e., pore morphology, alignment, average size distribution, etc.) by controlling the fabrication conditions and freezing kinetics. Furthermore, its combination with DOD printing provides the capability of engineering the macrostructure without relying on a mold as reported for 3D freeze-printed aerogels made from graphene, silver nanowires, and other nanocomposites. In this paper, we performed in-situ X-ray imaging to understand the inside process dynamics in 3DFP using a commercially available colloidal silica ink. We investigated the 3DFP process with the following hierarchy: first, single droplets; then, uniform lines obtained from coalescence of droplets; and finally, three consecutive lines deposited layer by layer. With the help of X-ray imaging, the importance of the balance between material deposition and freezing rates was shown in-situ by the observation inside of the freeze front following the tip of the printed line. The effects of the substrate temperature on the elimination of undesired interfacial boundaries were also shown by the observed ice crystals penetrating from lower to upper layer.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Inverse Mapping of the Collision Kernel and Wall Flux Scaling in a Tall Convection‐Cloud Chamber Using Local Sensors and Knowledge‐Informed Deep Learning

Droplet collision–coalescence is a crucial process in cloud physics, but accurately representing this process under different dynamical conditions remains challenging. A proposed future convective‐cloud chamber aims to investigate this key process, but the method for observing it remains unclear, even though it is theoretically established that collision‐coalescence will occur. This study serves as a proof‐of‐concept demonstration of how knowledge‐informed deep learning, combined with measurement data from local sensors in the chamber, can be used to estimate the collision kernels, which determine how the droplet size distribution evolves during collision‐coalescence. In addition to estimating the collision kernel, we also address wall fluxes, another uncertain but important process that acts as a source of heat and moisture in the chamber. Ensemble runs of large‐eddy simulations are conducted by scaling the wall fluxes and the collision kernel, while the measured flow and cloud properties are used as inputs for a neural network. Results indicate that this approach successfully maps the scaling of wall fluxes and the collision kernel with biases of approximately 1% or less relative to the range of the target data. This proof‐of‐concept lays the groundwork for future applications; when the real measurements are available, real sensor data combined with the trained model presented in this work will enable estimation of the actual wall fluxes and collision kernel.

cloud chamber↗
DOE OSTI2024

Reduced‐Order Modeling for Linearized Representations of Microphysical Process Rates

Abstract Representing cloud microphysical processes in large scale atmospheric models is challenging because many processes depend on the details of the droplet size distribution (DSD, the spectrum of droplets with different sizes in a cloud). While full or partial statistical moments of droplet size distributions are the typical variables used in bulk models, prognostic moments are limited in their ability to represent microphysical processes across the range of conditions experienced in the atmosphere. Microphysical parameterizations employing prognostic moments are known to suffer from structural uncertainty in their representations of inherently higher dimensional cloud processes, which limit model fidelity and lead to forecasting errors. Here we investigate how data‐driven reduced‐order modeling can be used to learn predictors for microphysical process rates in bulk microphysics schemes in an unsupervised manner from higher dimensional bin distributions. Using simulations characteristic of marine stratiform clouds, we simultaneously learn lower dimensional representations of droplet size distributions and predict the evolution of the microphysical state of the system. Droplet collision‐coalescence, the main process for generating warm rain, is estimated to have an intrinsic dimension of three. This intrinsic dimension provides a lower limit on the number of degrees of freedom needed to accurately represent collision‐coalescence in models. We demonstrate how deep learning based reduced‐order modeling can be used to discover intrinsic coordinates describing the microphysical state of the system, where process rates such as collision‐coalescence are globally linearized. These implicitly learned representations of the DSD retain more information about the DSD than typical moment‐based representations.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Study of Stratus-Lowering Marine-Fog Events Observed During C-FOG

Two stratus lowering marine fog events observed on 28 September and 04 October 2018 during the Coastal Fog (C-Fog) field campaign that took place offshore of Eastern Canada during 1 September to 6 October 2018 are described. In-situ, profiling and remote sensing observations were made at selected land sites in eastern Newfoundland (NL) and Nova Scotia (NS) as well as aboard the research vessel (R/V) Hugh R. Sharp that cruised in adjoining coastal waters. Synoptic scale analysis showed that both fog episodes were an outcome of the interaction between synoptic-scale surface level low-pressure systems and a contiguous high-pressure system. At the same time, back trajectories revealed that the bulk of the fog layer is formed due to differential advection. Here, the diameter of the fog droplets at the surface gradually decreased from the centre of the fog layer to its leading/trailing edges. The bimodal fog droplet diameter distribution with peaks at 5-10 µm and 20-25 µm provided clues on droplet collision and coalescence processes. The observed difference between microphysical variables and droplet distribution between the two fog events and within same fog layer may have been governed by atmospheric boundary layer conditions (e.g., humidity conditions and turbulence) prevailed in the fog layer. Overall, it is concluded that the life cycle of observed stratus-lowering coastal-fog episodes is dependent on synoptic conditions as well as atmospheric boundary layer characteristics such as stability, cloud top cooling and entrainment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Coalescence and splashing threshold for head-on collisions of liquid metal nanodroplets

Head-on collisions of liquid metal nanodroplets in a vacuum are investigated through molecular dynamics simulations in order to determine the transition threshold between the coalescing and splashing regimes for six different materials (aluminum, calcium, cerium, gold, platinum, and tin). Droplets of various sizes and initial speeds are simulated, and it is found that the Reynolds and Ohnesorge numbers are able to predict the transition between the coalescing and splashing regimes. An energy balance for coalescing droplets shows that the initial energy is mainly converted to thermal energy increasing the temperature of the combined droplets by several hundred to several thousand kelvin depending on the material, and this result is confirmed in the simulations. Furthermore, when splashing occurs, the number of smaller droplets formed and the spreading rate are found to be dependent on the initial size and initial speed of the original droplets.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Coalescence-Induced Spontaneous Shedding of Microdroplets on Superhydrophobic Surfaces Featuring Enclosed Micropillars with Hierarchical Roughness

This study investigated water vapor condensation on superhydrophobic surfaces (SHSs) featuring micropillars enclosed by wall lattices and having three-tier hierarchical roughness. A total of five samples were created with three (NW-J, W200-J and W400-J samples) having large micropillar depth (~6 μm) and two (NW-S and W200-S samples) having small micropillar depth (~1 μm). Two distinct condensate removal modes were observed during condensation: coalescence-induced jumping on samples with large micropillar depth and coalescence-induced shedding on samples with small micropillar depth. The results showed that the diameter of the shedding droplet on the W200-S sample having small micropillar depth could be as small as 107 μm, as compared to the theoretical critical diameter of 267 μm for gravitational shedding on the same sample. The enhanced functionality of the three-tier nanotextures on the W200-S sample could effectively suppress localized pinning of the three-phase contact line and Wenzel neck formation during the growth of condensate droplets. Consequently, during multidroplet coalescence, the released surface energy easily overcomes the solid–liquid adhesion, leading to spontaneous shedding of merged droplets. The inclusion of the wall lattice aids condensate growth by the droplet self-alignment along the walls and promoting coalescence. As a result, the W200-S sample exhibited the highest condensate collection as well. In conclusion, the proposed surface design has great potential for scaling up and implementation in heating, ventilation, and air-conditioning equipment due to the simplicity of the surface morphology and the facile spray-coating method used to achieve hierarchical roughness.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Spanning the Gap From Bulk to Bin: A Novel Spectral Microphysics Method

Microphysics methods for climate models and numerical weather prediction typically track one, two, or three moments of a droplet size distribution for various categories of liquid, ice, and aerosol. Such methods rely on conversion parameters between these categories, which introduces uncertainty into predictions. While higher-fidelity options such as bin and Lagrangian schemes exist, they require too many degrees of freedom for climate modeling applications and introduce numerical challenges. Here we introduce a flexible spectral microphysics method based on collocation of basis functions. This method generalizes to a linear bulk scheme when using few basis functions and to a smoothed bin scheme with more degrees of freedom. Tested in an idealized box setting, the method improves spectral accuracy for droplet collision-coalescence and may eliminate the need for precipitation autoconversion rates required by bulk methods; furthermore, it generalizes well to multimodal distributions with less complexity than a bin method. The potential to extend this collocation representation to multiple hydrometeor classes suggests a path forward to unify liquid, ice, and aerosol microphysics in a single, flexible, computational framework for climate modeling.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Evaluating the Collision‐Coalescence Process in Idealized Cloud Convection Using Large‐Eddy Simulations With Lagrangian Microphysics

Drizzle initiation through the collision and coalescence of cloud droplets plays a crucial role in warm cloud precipitation. Recent theoretical studies suggest that the influence of collisional growth on the droplet size distribution can be quantified by a non-dimensional drizzle number (Dz). Here, large-eddy simulations with Lagrangian microphysics are employed to evaluate the theory by simulating a tall convection-cloud chamber under various conditions. Results show that the smaller the Dz, the larger the impact of collisions on the right tail of the droplet size distribution, consistent with the theory. The simulations confirm that the collision rate can be estimated from the droplet size distribution interacting only with cloud droplets of the same size at the mode radius. This suggests that the idealized theory can be a useful tool to design a cloud chamber for drizzle investigation, as well as to represent drizzle formation in models of real atmospheric clouds.

54 ENVIRONMENTAL SCIENCES↗