An experimental investigation was performed to study the influence of the bubble size on an effervescent atomization. Experiments were conducted in horizontal facility with a 25.4mm diameter feeding pipe using water and air as the working fluids that were sprayed through an effervescent nozzle. Water flow rates from 113 to 189 kg/min and air to liquid mass ratios from 1% to 4% were selected. High speed photographs, of the bubbles in the feeding conduit and of the resulting droplets on the spray, were taken to use the particle projected areas to estimate their sizes. A monotonic positive correlation was found between the bubble size and the droplet size, in a fairly narrow range of feed flow void fractions. A bubble size sensitivity parameter was defined. Knowledge of the droplet behaviour provides data to enhance the design and operating conditions of the atomization process and a means to control droplet size.

An experimental investigation was performed to study the influence of the bubble size on an effervescent atomization. Experiments were conducted in horizontal facility with a 25.4mm diameter feeding pipe using water and air as the working fluids that were sprayed through an effervescent nozzle. Water flow rates from 113 to 189 kg/min and air to liquid mass ratios from 1% to 4% were selected. High speed photographs, of the bubbles in the feeding conduit and of the resulting droplets on the spray, were taken to use the particle projected areas to estimate their sizes. A monotonic positive correlation was found between the bubble size and the droplet size, in a fairly narrow range of feed flow void fractions. A bubble size sensitivity parameter was defined. Knowledge of the droplet behaviour provides data to enhance the design and operating conditions of the atomization process and a means to control droplet size.

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Effervescent atomization has been a topic of considerable investigation in the literature due to its important advantages over other atomization mechanisms. This work contributes to the development of both effervescent atomizers and also laser-based techniques for spray investigation In order to develop non-intrusive measurement techniques for spray applications, a procedure is suggested to characterize the shape of droplets using image-based droplet analyzers. Image discretization which is a major source of error in droplet shape measurement is evaluated using a simulation. The accuracy of StereoPIV system in conducting droplet velocity measurement in a spray field is also investigated. To assist in the design of effervescent atomizers, bubble formation during gas injection from a micro-tube into liquid cross-flow is investigated using a Shadow-PIV/PTV system. The generated spray fields of two effervescent atomizers which operate using a porous and a typical multi-hole air injector are compared using qualitative images and Shadow-PTV measurement.

The main aim of this project is to model the effects of varied injection parameters on the gas dynamics and droplet dynamics of the HVSFS and SP- HVOFS processes for improving the droplet breakup and evaporation to enhance the nanoparticles heating and deposition efficiency. Thermal spraying processes are widely used to generate thermal-, corrosion-, and wear-resistant layers over the machine parts, to increase the durability of the equipment under severe environmental conditions. The liquid feedstock is used to achieve nanostructured coatings. It is used either in the form of a suspension or a solution precursor. The suspension is a mixture of solid nanoparticles suspended in a liquid medium consisting, for instance, of water, ethanol, or isopropanol. This dispersion mechanism in a liquid carrier provides adequate flowability to the nanoparticles, which cannot be handled by conventional gas- based feeding systems, whereas the solution precursor is mixed at the molecular level; hence, more uniform phase composition and properties are expected in the sprayed coatings as compared to the suspension and conventional powder spraying. Firstly, experiments are conducted to analyse the effects of different precursor concentrations, solvent types and injection nozzles on the size and morphology of synthesized nanoparticles. The results indicate that the particle size increased with increasing precursor concentration due to the variations in the physical properties of the mixture solution. The higher precursor concentrations had an adverse effect on the droplet atomization and evaporation process that led to bigger size particle formation. The use of aqueous solvent has some limits and with higher precursor concentration the surface tension increases that resulted in the reduction of droplets’ disintegration, and thus bigger size precursor droplets generate larger nanoparticles. A mixture of aqueous-organic solvents and pure organic precursors are preferred to improve the process efficiency of the nanoparticles size and morphology. Furthermore, the nanoparticles size can be controlled by using liquid feedstock atomization before injecting into the HVOF torch. A new effervescent injection nozzle is designed and compared to different types of existing injection nozzles, to see the variations in the droplet disintegration, and its effects on the performance of the HVOF torch processes. It is detected that the atomization would result in smaller size particles with homogeneous morphology. In a numerical study, different droplet injection types are analysed to see their effects on the gas and droplet dynamics inside the HVOF torch. The group-type injection (GTI) and effervescent-type atomization (ETI) are used effectively to overcome the heat losses and delays in the droplet evaporation. These approaches reduce the thermal and kinetic energy losses in the suspension-fed-HVOF torch, thereby improving the coating formation. The effects of using multicomponent water-ethanol mixture injection in the HVOF torch are also modelled, and its impact on the droplet breakup and evaporation are studied. The organic solvents have a low heat of vaporization and surface tension, and can effectively be used in the HVOF spraying process over the water-based solvents. Furthermore, nanoparticles are suspended in the liquid feedstock and injected into the HVOF torch. The effect of increasing nanoparticles’ concentration in the feedstock and its consequence on the gas dynamics, droplet breakup and evaporation are analysed. The augmentation in the nanoparticles loading in the suspension droplets can decrease the droplet breakup and evaporation rate because the required heat of vaporization increases significantly. Moreover, the size of injection droplet affects the droplet fragmentation process; bigger sized droplets observed a delay in their evaporation that resulted in coating porosity. The results suggest that smaller droplet sizes are preferred in coating applications involving a higher concentration of nanoparticles with high melting point. Further, the gas flow rates (GFRs) are regulated to control the droplet dispersion, atomization and evaporation inside the solution precursor fed-HVOF torch. The size of the droplet diameter is decreased by an increment in the GFR, as higher combustion rates increase the combustion flame enthalpy and kinetic energy. Moreover, the increase in the oxygen/fuel flow rates dilutes the injected precursor. It reduces ZrO2 concentration in the process and decreases the rate of particle collision; as a result, non-agglomerated nanoparticles can be obtained.

Tato práce se zaměřuje na oblast effervescentních sprejů a jejich aplikace na kapalné spalování s důrazem na průmyslové spalovací komory. Oba aspekty – modelování a experiment – jsou řešeny. Práce obsahuje obecný úvod, ve kterém jsou vysvětleny základní jevy rozpadu kapaliny a vířivého spalování a dále je představena effervescentní atomizace. Poté jsou popsány použité experimentální postupy jak pro měření spreje, tak pro měření tepelných toků do stěn při spalování. V následující kapitole jsou popsány numerické modely a jejich podstata je vysvětlena. Jsou zde uvedeny modely pro rozpad spreje, turbulenci a spalování použité během výzkumu. Vlastní výsledky práce jsou uvedeny formou samostatných článků (vydaných nebo přijatých) s dodatečnou částí věnovanou nepublikovaným relevantním výsledkům. Bylo zjištěno, že standardní modely sprejů jsou do jisté míry schopny popsat effervescentní spreje. Nicméně aby bylo možné predikovat plamen kapalného spreje, jsou zapotřebí detailnější modely sprejů, které dokáží přesně zachytit změnu průměrů kapek v radiálním a axiálním směru. Experimentální měření effervescentních sprejů bylo provedeno pomocí navrhnuté metodiky. Výsledky měření byly analyzovány s důrazem na radiální a axiální vývoj průměrů kapek a některé nové jevy byly popsány. Nepřímá úměrnost mezi gas-liquid-ratio a středním průměrem kapek byla potvrzena. Dále by popsán jev, kdy pro různé axiální vzdálenosti které dojde k úplnému převrácení závislosti středního průměru na axiální vzdálenosti. V závěru je uvedeno shrnutí, které rekapituluje hlavní výsledků a závěry. V závěrečných poznámkách je nastíněn možný budoucí postup. Experimentální data pro ověřování budoucích effervescentních modelů jsou poskytnuta.

Atomization of fuel is an important pre-requisite for efficient combustion in devices such as gas turbines, liquid propellant rocket engines, internal combustion engines and incinerators. The overall objective of the present work is to explore air-assisted atomization strategies for high viscosity fuels and liquids. Air-assisted atomization is a twin-fluid atomization method in which energy of the gas is used to assist the atomization of liquids. Broadly, three categories of air-assisted injection, i.e., effervescent, impinging jet and pre-filming air-blast are studied. Laser-based diagnostics are used to characterize the spray structure in terms of cone angle, penetration and drop size distribution. A backlit direct imaging method is used to study the macroscopic spray characteristics such as spray structure and spray cone angle while the microscopic characteristics are measured using the Particle/droplet imaging analysis (PDIA) technique. Effervescent atomization is a technique in which a small amount of gas is injected into the liquid at high pressure in the form of bubbles. Upon injection, the two-phase mixture expands rapidly and shatters the liquid into droplets and ligaments. Effervescent spray characteristics of viscous fuels such as Jatropha and Pongamia pure plant oils and diesel are studied. Measurements are made at various gas-to-liquid ratios (GLRs) and injection pressures. A Sauter Mean Diameter (SMD) of the order of 20 µm is achieved at an injection pressure of 10 bar and GLR of 0.2 with viscous fuels. An image-based method is proposed and applied to evaluate the unsteadiness in the spray. A map indicating steady/unsteady regime of operation has been generated. An optically accessible injector tip is developed which has enabled visualization of the two-phase flow structure inside the exit orifice of the atomizer. An important contribution of the present work is the correlation of the two-phase flow regime in the orifice with the external spray structure. For viscous fuels, the spray is observed to be steady only in the annular two-phase flow regime. Unexpanded gas bubbles observed in the liquid core even at an injection pressure of 10 bar indicate that the bubbly flow regime may not be beneficial for high viscosity oils. A novel method of external mixing twin-fluid atomization is developed. In this method, two identical liquid jets impinging at an angle are atomized using a gas jet. The effect of liquid viscosity (1 cP to 39 cP) and surface tension (22 mN/m to 72 mN/m) on this mode of atomization is studied by using water-glycerol and water-ethanol mixtures, respectively. An SMD of the order of 40 µm is achieved for a viscosity of 39 cP at a GLR of 0.13 at a liquid pressure of 8 bar and gas pressure of 5 bar. It is observed that the effect of liquid properties is minimal at high GLRs where the liquid jets are broken before the impingement as in the prompt atomization mode. Finally, a pre-filming air-blast technique is explored for transient spray applications. An SMD of 22 µm is obtained with diesel at liquid and gas pressures as low as 10 bar and 8.5 bar, respectively. With this technique, an SMD of 44 µm is achieved for Jatropha oil having a viscosity 10 times higher than that of diesel.