Alternative methods for surface texturing

Surface texturing has a great potential to improve tribological performance. First, possible texturing methods were identified and classified according to their physical principles. In sequence, some alternative texturing methods are presented. Some of them are already currently used either in industry or in laboratory, and innovations or simplifications are described for them. Others are innovative techniques. Some were explored only tentatively, where basic ideas and simple experimental investigations were developed to check their validity. Others were explored in more detail, so that their practical applicability could be identified. The first texturing method was photochemical texturing using a simple and cheap apparatus. Masking with inkjet printing before chemical etching was also successful to texture metallic samples. A new method involving electrochemical texturing, without the need to previously mask the samples to be textured have been studied in terms of voltage, current, mechanical configuration of the apparatus and electrolyte flushing. Another method aims to generate randomly distributed circular pockets on steel surfaces and involves dispersion of small acid droplets in oil. The final method involves the selective formation of hard areas on a steel surface by locallised diffusion, which should then develop into a texture during wear.

Experimental observation of von Kármán vortices during drop impact

The observation of von Kármán type vortices during the impact of water droplets onto a pool of water is reported. Shadowgraph imaging and laser-sheet visualization are used to document these events. The appearance of these vortices occurs within theoretically predicted regions in a Reynolds-splash number parameter space. In addition, and also in agreement with theoretical predictions, smooth splashing, with vortices absent, is found for smaller Reynolds number. © 2012 American Physical Society.

How PEDOT:PSS solutions produce satellite-free inkjets

Satellite droplets are unwanted in inkjet printing and various approaches have been suggested for their reduction. Low jetting speeds limit applications of the process. Added surfactants for wetting and conductivity enhancement may help but dynamic surface tension effects may counteract improvements. A higher fluid viscosity delays ligament break-up, but also leads to slower jets, while viscoelasticity reduces satellite formation only in certain cases. We show here that aqueous solutions of PEDOT:PSS (1:2.5 by weight) are strongly shear-thinning. They exhibit low viscosity within the printing nozzle over a wide range of jet speeds, yet rapidly (<100 μs) recover a higher viscosity at the low shear rates applicable once the jet has formed, which give the benefit of delayed satellite formation. The delay over a 0.8 mm stand-off distance can be sufficient to completely suppress satellites, which is significant for many printing applications. © 2012 Elsevier B.V. All rights reserved.

Experimental observation of von Kármán vortices during drop impact.

The observation of von Kármán type vortices during the impact of water droplets onto a pool of water is reported. Shadowgraph imaging and laser-sheet visualization are used to document these events. The appearance of these vortices occurs within theoretically predicted regions in a Reynolds-splash number parameter space. In addition, and also in agreement with theoretical predictions, smooth splashing, with vortices absent, is found for smaller Reynolds number.

Time-resolved particle image velocimetry within the nozzle of a drop-on-demand printhead

Time-resolved particle image velocimetry (PIV) has been performed inside the nozzle of a commercially available inkjet print-head to obtain the time-dependent velocity waveform. A printhead with a single transparent nozzle 80 μm in orifice diameter was used to eject single droplets at a speed of 5 m/s. An optical microscope was used with an ultra-high-speed camera to capture the motion of particles suspended in a transparent liquid at the center of the nozzle and above the fluid meniscus at a rate of half a million frames per second. Time-resolved velocity fields were obtained from a fluid layer approximately 200 μm thick within the nozzle for a complete jetting cycle. A Lagrangian finite-element numerical model with experimental measurements as inputs was used to predict the meniscus movement. The model predictions showed good agreement with the experimental results. This work provides the first experimental verification of physical models and numerical simulations of flows within a drop-on-demand nozzle. © 2012 Society for Imaging Science and Technology.

Mechanics of capillary forming of aligned carbon nanotube assemblies.

Elastocapillary self-assembly is emerging as a versatile technique to manufacture three-dimensional (3D) microstructures and complex surface textures from arrangements of micro- and nanoscale filaments. Understanding the mechanics of capillary self-assembly is essential to engineering of properties such as shape-directed actuation, anisotropic wetting and adhesion, and mechanical energy transfer and dissipation. We study elastocapillary self-assembly (herein called "capillary forming") of carbon nanotube (CNT) microstructures, combining in situ optical imaging, micromechanical testing, and finite element modeling. By imaging, we identify sequential stages of liquid infiltration, evaporation, and solid shrinkage, whose kinetics relate to the size and shape of the CNT microstructure. We couple these observations with measurements of the orthotropic elastic moduli of CNT forests to understand how the dynamic of shrinkage of the vapor-liquid interface is coupled to the compression of the forest. We compare the kinetics of shrinkage to the rate of evporation from liquid droplets having the same size and geometry. Moreover, we show that the amount of shrinkage during evaporation is governed by the ability of the CNTs to slip against one another, which can be manipulated by the deposition of thin conformal coatings on the CNTs by atomic layer deposition (ALD). This insight is confirmed by finite element modeling of pairs of CNTs as corrugated beams in contact and highlights the coupled role of elasticity and friction in shrinkage and stability of nanoporous solids. Overall, this study shows that nanoscale porosity can be tailored via the filament density and adhesion at contact points, which is important to the development of lightweight multifunctional materials.

Spray flame study using a model gas turbine swirl burner

A model gas turbine burner was employed to investigate spray flames established under globally lean, continuous, swirling conditions. Two types of fuel were used to generate liquid spray flames: palm biodiesel and Jet-A1. The main swirling air flow was preheated to 350°C prior to mixing with airblast-atomized fuel droplets at atmospheric pressure. The global flame structure of flame and flow field were investigated at the fixed power output of 6 kW. Flame chemiluminescence imaging technique was employed to investigate the flame reaction zones, while particle imaging velocimetry (PIV) was utilized to measure the flow field within the combustor. The flow fields of both flames are almost identical despite some differences in the flame reaction zones. © (2013) Trans Tech Publications, Switzerland.

Time resolved measurement of cold start hc concentration using the fast FID

Understanding mixture formation phenomena during the first few cycles of an engine cold start is extremely important for achieving the minimum engine-out emission levels at the time when the catalytic converter is not yet operational. Of special importance is the structure of the charge (film, droplets and vapour) which enters the cylinder during this time interval as well as its concentration profile. However, direct experimental studies of the fuel behaviour in the inlet port have so far been less than fully successful due to the brevity of the process and lack of a suitable experimental technique. We present measurements of the hydrocarbon (HC) concentration in the manifold and port of a production SI engine using the Fast Response Flame Ionisation Detector (FRFID). It has been widely reported in the past few years how the FRFID can be used to study the exhaust and in-cylinder HC concentrations with a time resolution of a few degrees of crank angle, and the device has contributed significantly to the understanding of unburned HC emissions. Using the FRFID in the inlet manifold is difficult because of the presence of liquid droplets, and the low and fluctuating pressure levels, which leads to significant changes in the response time of the instrument. However, using recently developed procedures to correct for the errors caused by these effects, the concentration at the sampling point can be reconstructed to align the FRFID signal with actual events in the engine. © 1996 Society of Automotive Engineers, Inc.

The dominant role of the solvent-water interface in water droplet templating of polymers

We investigate the formation of microstructured polymer networks known as Breath Figure templated structures created by the presence of water vapour over evaporating polymer solutions. We use a highly controlled experimental approach to examine this dynamic and non-equilibrium process to uniquely compare pure solvent systems with polymer solutions and demonstrate using a combination of optical microscopy, focused ion-beam milling and SEM analysis that the porous polymer microstructure is completely controlled by the interfacial forces that exist between the water droplet and the solvent until a final drying dilation of the imprints. Water droplet contact angles are the same in the presence or absence of polymer and are independent of size for droplets above 5 μm. The polymer acts a spectator that serves to trap water droplets present at the air interface, and to transfer their shape into the polymer film. For the smallest pores, however, there are unexpected variations in the contact angle with pore size that are consistent with a possible contribution from line tension at these smaller dimensions. © The Royal Society of Chemistry.

Spray flame structure of rapeseed biodiesel and Jet-A1 fuel

The spray combustion characteristics of rapeseed methyl esters (RME) were compared to Jet-A1 fuel using a gas turbine type combustor. The swirling spray flames for both fuels were established at a constant power output of 6 kW. The main swirling air flow was preheated to 350 C prior to coaxially enveloping the airblast-atomized liquid fuel spray at atmospheric pressure. Investigation of the fundamental spray combustion was performed via measurements of the fuel droplet sizes and velocities, gas phase flow fields and flame reaction zones. The spray flame droplets and flow fields in the combustors were characterised using phase Doppler anemometry (PDA) and particle imaging velocimetry (PIV) respectively. Flame chemiluminescence imaging was employed to identify the flame reaction zones. The highest droplet concentration zone extends along a 30 angle from the symmetry axis, inside the flame zone. Only small droplets(<17 μ) (<17 μm)are found around the centreline region, while larger droplets are found at the edge of the spray outside the flame reaction zone. RME exhibits spray characteristics similar to Jet-A1 but with droplet concentration and volume fluxes four times higher, consistent with the expected longer droplet evaporation timescale. The flow field characteristics for both RME and Jet-A1 spray flames are very similar despite the significantly different visible characteristics of the flame reaction zones. © 2013 Elsevier Ltd. All rights reserved.

Sensors based on SAW and FBAR technologies

Over the last few years a number of sensing platforms are being investigated for their use in drug development, microanalysis or medical diagnosis. Lab-on-a-chip (LOC) are devices integrating more than one laboratory functions on a single device chip of a very small size, and typically consist of two main components: microfluidic handling systems and sensors. The physical mechanisms that are generally used for microfluidics and sensors are different, hence making the integration of these components difficult and costly. In this work we present a lab-on-a-chip system based on surface acoustic waves (for fluid manipulation) and film bulk acoustic resonators (for sensing). Coupling surface acoustic waves into liquids induces acoustic streaming and motion of micro-droplets, whilst it is well-known that bulk acoustic waves can be used to fabricate microgravimetric sensors. Both technologies offer exceptional sensitivity and can be fabricated from piezoelectric thin films deposited on Si substrates, reducing the fabrication time/cost of the LOC devices. © 2013 SPIE.

Future, opportunities and challenges of inkjet technologies

Inkjet printing relies on the formation of small liquid droplets to deliver precise amounts of material to a substrate under digital control. Inkjet technology is becoming relatively mature and is of great industrial interest thanks to its flexibility for graphical printing and its potential use in less conventional applications such as additive manufacturing and the production of printed electronics and other functional devices. Its advantages over traditional methods of printing include the following: it produces little or no waste, it is versatile because several different methods exist, it is noncontact, and it does not require a master template so that printed patterns can be readily modified on demand. However, the technology is in need of further development to become mainstream in emerging applications such as additive manufacturing (3D printing). This review contains a description of conventional and less common inkjet methods and surveys the current applications of inkjet in industry. This is followed by specific examples of the barriers, limitations, and challenges faced by inkjet technology in both graphical printing and manufacturing. © 2013 by Begell House, Inc.

On-chip switching of a silicon nitride micro-ring resonator based on digital microfluidics platform.

We demonstrate the switching of a silicon nitride micro ring resonator (MRR) by using digital microfluidics (DMF). Our platform allows driving micro-droplets on-chip, providing control over the effective refractive index at the vicinity of the resonator and thus facilitating the manipulation of the transmission spectrum of the MRR. The device is fabricated using a process that is compatible with high-throughput silicon fabrication techniques with buried highly doped silicon electrodes. This platform can be extended towards controlling arrays of micro optical devices using minute amounts of liquid droplets. Such an integration of DMF and optical resonators on chip can be used in variety of applications, ranging from biosensing and kinetics to tunable filtering on chip.

Water droplet flow paths and droplet deposition in low pressure steam turbines

The complex three-dimensional two-phase flow in a low pressure steam turbine is investigated with comprehensive numerical flow simulations. In addition to the condensation process, which already takes place in the last stages of steam turbines, the numerical flow model is enhanced to consider the drag forces between the droplets and the vapour phase. The present paper shows the differences in the flow path of the phases and investigates the effect of an increasing droplet diameter. For the flow simulations a performance cluster is used because of the high effort for such multi-momentum two-phase flow calculations. In steam turbines the deposition of small water droplets on the stator blades or on parts of the casing is responsible for the formation of large coarse water droplets and these may cause additional dissipation as well as damage due to blade erosion. A method is presented that uses detailed CFD data to predict droplet deposition on turbine stator blades. This simulation method to detect regions of droplet deposition can help to improve the design of water removal devices. © Springer-Verlag Berlin Heidelberg 2013.

On-chip tunable micro-ring resonator based on digital microfluidics platform

We demonstrate the tunability of a silicon nitride micro-resonator using the concept of Digital Microfluidics. Our system allows driving micro-droplets on-chip, enabling the control of the effective refractive index at the vicinity of the resonator. © 2010 OSA/FiO/LS 2010.