The emerging paradigms of shockwave research have opened up new horizons for interdisciplinary applications. This has inevitably driven research towards studying the propagation of shockwaves in miniature shock tubes (tube diameters typically in the range of 1−10 ). Studies have revealed that while operating at this diameter range and low initial pressures (typically 1 < 100 ) leading to low values of characteristic Reynolds numbers (typically ′ < 23,000 −1), results in the boundary layer playing a major role in shockwave attenuation. But there are very few studies addressing shockwave attenuation when shock tubes are operated at higher Reynolds number. Pressure measurements and visualization studies in shock tubes of these length scales are also seldom attempted due to practical difficulties. Given that premise, in the present work the shockwave attenuation due to wall effects and non-ideal diaphragm rupture in shock tubes of hydraulic diameters 2 , 6 and 10 has been investigated at ambient initial driven section conditions ( 1 = 300 and 1 = 1 resulting in Reynolds number in the range 70,212 −1 – 888,627 −1). In this study pressure measurements and high-speed visualization have been carried out to find the effect of the pressure ratio, temperature ratio and molecular weights of driver gas on the shock attenuation processes. In order to study the effects of the driver/driven gas temperature ratios on the shock attenuation process, a new in-situ oxyhydrogen (hydrogen and oxygen gases in the ratio 2:1) generator has been developed. Using this innovative device, the miniature shock tubes are also run in the detonation mode (forward facing detonation wave). The results obtained using helium and nitrogen driver gases for these shock tubes reveal that as the hydraulic diameter of the shock tube is reduced, a larger diaphragm pressure ratio is required to obtain a particular strength of shockwave. The attenuation in the shockwave is found to be a function of the driver gas properties namely specific heat ratio ( 4), molecular weight ( 4), temperature ( 4) as well as the diaphragm opening time of the shock tube in addition to the parameters , 21, / , and 1 as already suggested in previous reports. The visualization studies reveal that the effect of diaphragm opening time leading to longer shock formation distances appears to influence the shockwave attenuation process at these shock tube diameters. Further, it is also found that the strength of the shockwave reduces when the ratio 4/ 1 is higher. It is also seen that the length of the driven sections must be less than twice the length of the driver sections to reduce attenuation. Based on the understanding of the nature of supersonic flow in a miniature shock tubes, a novel shock/blast wave device has been developed for certain innovative biotechnology applications such as needleless vaccine delivery and cell transformations. The new device has an internal diameter of 6 and by varying the length of the driver/driven sections either shock or blast waves of requisite strength and impulse can be generated at the open end of the tube. In the shock tube mode of operation, shockwaves with steady time duration of up to 30 have been generated. In the blast tube mode of operation, where the entire tube is filled with oxyhydrogen mixture, shockwaves with peak pressures of up to 550 have been obtained with good repeatability. An attempt to power this device using solar energy has also given successful results. Visualization of the open end of the detonation driven shock tube reveals features typical of flow from the open end of shock tubes and has helped in quantifying the density field. The subsequent instants of the flow resemble a precursor flow in gun muzzle blast and flash. Typical energy levels of the shock/blast waves coming out this device is found to be about 34 for an oxyhydrogen fill pressure of 5.1 in the shock tube operation mode. Transformation of E.coli, Salmonella Typhimurium and Pseudomonas aeruginosa bacterial strains using the device by introducing plasmid DNA through their cell walls has been successfully carried out. There is more than twofold increase in the transformation efficiency using the device as compared to conventional methods. Using the same device, needleless vaccine delivery in mice using Salmonella has also been demonstrated successfully. Overall, in the present thesis, a novel method for generating shockwaves in a repeatable and controllable manner in miniature scales for interdisciplinary applications has been proposed. Also, it is the first time that experiments with the different diameter miniature shock tubes have been carried out to demonstrate the attenuation of shockwaves as the hydraulic diameter of the shock tube decreases. Future research endeavors will focus on quantitative measurement of the particle velocity behind the shock waves, and also on the nature of the boundary layers to further resolve the complex flow physics associated with supersonic flows in these miniature shock tubes.

Master’s thesis deals with aerodynamic heating of launch vehicle during ascent phase by using CFD simulation. Ascent trajectory and payload fairing geometry is design using data of existing small launch vehicles. Critical flight regimes are identified using 2D calculations, and in these regimes analysis is performed by axially symmetric simulations. Simulation results are compared to values obtained from theoretical and semi-empirical calculations.

Ce travail de thèse concerne l’étude des écoulements de fluides gazeux compressibles laminaires subsonique-supersonique dans une tuyère de type convergent-divergent. Les écoulements étudiés sont à nombres de Reynolds modérés et s’affranchissent de l’hypothèse de condition adiabatique de paroi couramment utilisée afin de mieux prendre en compte les phénomènes de transfert de chaleur par convection et rayonnement avec le milieu extérieur. Cette étude des phénomènes de transferts conjugués a permis de déterminer le comportement dynamique simultané du fluide et de la paroi de la tuyère. Enfin, compte tenu des niveaux élevés de températures mis en jeu dans ces systèmes, une analyse concernant le comportement thermomécanique de l’ensemble de la structure de paroi avec des matériaux monocouches et multicouches a été réalisé. De nombreuses configurations géométriques, propriétés physiques et conditions aux limites sur le fluide et la paroi ont été analysées. Les résultats présentés montrent, la structure des écoulements à travers les iso-contours de vitesses, des nombres de Mach, des pressions dans le fluide, des températures dans le fluide et dans la paroi ainsi que les déformations et les contraintes de la paroi qui résultent des couplages thermomécaniques. Une analyse des performances de la tuyère, en termes de force de poussée et de coefficient de débit spécifique, est largement discutée dans ce travail. / This work concerns the study of flows of compressible gaseous laminar subsonic-supersonic nozzle in a convergent-divergent type. The flows are studied to moderate Reynolds numbers and free themselves from the assumption of adiabatic wall conditions commonly used to better take into account the phenomena of heat transfer by convection and radiation with the external environment. This study combined transfer phenomena was determined simultaneously the dynamic behavior of the fluid and the wall of the nozzle. Finally, given high levels of temperatures at stake in these systems, an analysis of the thermomechanical behavior of the entire wall structure with monolayer and multilayer materials was performed. Many geometric configurations, physical properties and boundary conditions on the fluid and the wall were analyzed. The results presented show the structure of the flow through the iso-contours of speed, Mach numbers, pressures in the fluid, temperatures in the fluid and in the wall as well as the deformations and stresses resulting from the wall thermomechanical couplings. A performance analysis of the nozzle, in terms of thrust coefficient and specific yield, is widely discussed in this work.

Compressible plane Couette flow is studied with superposed small perturbations. The steady mean flow is characterized by a non-uniform shear-rate and a varying temperature across the wall-normal direction for an appropriate perfect gas model. The studies are broadly into four main categories as said briefly below. Nonmodal transient growth studies and estimation of optimal perturbations have been made. The maximum amplification of perturbation energy over time, G max, is found to increase with Reynolds number Re, but decreases with Mach number M. More specifically, the optimal energy amplification Gopt (the supremum of G max over both the streamwise and spanwise wavenumbers) is maximum in the incompressible limit and decreases monotonically as M increases. The corresponding optimal streamwise wavenumber, αopt, is non-zero at M = 0, increases with increasing M, reaching a maximum for some value of M and then decreases, eventually becoming zero at high Mach numbers. While the pure streamwise vortices are the optimal patterns at high Mach numbers (in contrast to incompressible Couette flow), the modulated streamwise vortices are the optimal patterns for low-to-moderate values of the Mach number. Unlike in incompressible shear flows, the streamwise-independent modes in the present flow do not follow the scaling law G(t/Re) ~ Re2, the reasons for which are shown to be tied to the dominance of some terms (related to density and temperature fluctuations) in the linear stability operator. Based on a detailed nonmodal energy anlaysis, we show that the transient energy growth occurs due to the transfer of energy from the mean flow to perturbations via an inviscid algebraic instability. The decrease of transient growth with increasing Mach number is also shown to be tied to the decrease in the energy transferred from the mean flow (E1) in the same limit. The sharp decay of the viscous eigenfunctions with increasing Mach number is responsible for the decrease of E1 for the present mean flow. Linear stability and the non-modal transient energy growth in compressible plane Couette flow are investigated for the uniform shear flow with constant viscosity. For a given M, the critical Reynolds number (Re), the dominant instability (over all stream-wise wavenumbers, α) of each mean flow belongs different modes for a range of supersonic M. An analysis of perturbation energy reveals that the instability is primarily caused by an excess transfer of energy from mean-flow to perturbations. It is shown that the energy-transfer from mean-flow occurs close to the moving top-wall for “mode I” instability, whereas it occurs in the bulk of the flow domain for “mode II”.For the Non-modal transient growth anlaysis, it is shown that the maximum temporal amplification of perturbation energy, G max,, and the corresponding time-scale are significantly larger for the uniform shear case compared to those for its non-uniform counterpart. For α = 0, the linear stability operator can be partitioned into L ~ L ¯ L +Re2Lp is shown to have a negligibly small contribution to perturbation energy which is responsible for the validity of the well-known quadratic-scaling law in uniform shear flow: G(t/Re) ~ Re2 . In contrast , the dominance of Lp is responsible for the invalidity of this scaling-law in non-uniform shear flow. An inviscid reduced model, based on Ellignsen-Palm-type solution, has been shown to capture all salient features of transient energy growth of full viscous problem. For both modal and non-modal instability, the viscosity-stratification of the underlying mean flow would lead to a delayed transition in compressible Couette flow. Modal and nonmodal spatial growths of perturbations in compressible plane Couette flow are studied. The modal instability at a chosen set of parameters is caused by the scond least-decaying mode in the otherwise stable parameter setting. The eigenfunction is accurately computed using a three-domain spectral collocation method, and an anlysis of the energy contained in the least-decaying mode reveals that the instability is due to the work by the pressure fluctuations and an increased transfer of energy from mean flow. In the case of oblique modes the stability at higher spanwise wave number is due to higher thermal diffusion rate. At high frequency range there are disjoint regions of instability at chosen Reynolds number and Mach number. The stability characteristics in the inviscid limit is also presented. The increase in Mach number and frequency is found to further destabilize the unstable modes for the case of two-dimensional(2D) perturbations. The behaviors of the non-inflexional neutral modes are found to be similar to that of compressible boundary layer. A leading order viscous correction to the inviscid solution reveals that the neutral and unstable modes are destabilized by the no-slip enforced by viscosity. The viscosity has a dual role on the stable inviscid mode. A spatial transient growth studies have been performed and it is found that the transient amplification is of the order of Reynolds number for a superposition of stationary modes. The optimal perturbations are similar to the streamwise invariant perturbations in the temporal setting. Ellignsen & Palm solution for the spatial algebraic growth of stationary inviscid perturbation has been derived and found to agree well with the transient growth of viscous counterpart. This inviscid solution captures the features of streamwise vortices and streaks, which are observed as optimal viscous perturbations. The temporal secondary instability of most-unstable primary wave is also studied. The secondary growth-rate is many fold higher when compared with that of primary wave and found to be phase-locked. The fundamental mode is more unstable than subharmonic or detuned modes. The secondary growth is studied by varying the parameters such as β, Re, M and the detuning parameter.

Shock wave-boundary layer interactions (SWBLIs) have been studied ex-tensively due to their practical importance in the design of high speed ve-hicles. These interactions, especially the ones leading to shock induced separation are typically unsteady in nature and can lead to large fluctuating pressure and thermal loads on the structure. The resulting shock oscil-lations are generally composed of high-frequency small-scale oscillations and low-frequency large-scale oscillations, the source of the later being a subject of intense recent debate. Motivated by these debates, we study in the present work, the SWBLI at a compression ramp and on a forward-facing step (FFS) at a Mach number of 2.5. In the case of compression ramps, a few ramp angles are studied ranging from small (10 degree) ramp angle to relatively large values of up to 28 degrees. The FFS configuration, which consists of a 90 degree step of height h, may be thought of as an extreme case of the compression ramp geometry, with the main geometri-cal parameter here being (h/δ), where δis the thickness of the oncoming boundary layer. This configuration is less studied and has some inherent advantages for experimentally studying SWBLI as the size of the separa-tion bubble is large. In the present experimental study, we use high-speed schlieren, unsteady wall pressure measurements, surface oil flow visualiza-tion, and detailed particle image velocimetry (PIV) measurements in two orthogonal planes to help understand the features of SWBLI in the com-pression ramp geometry and the forward-facing step case. The SWBLI at a compression ramp has been more widely studied, and our measurements show the general features that have been seen in earlier studies. The upstream boundary layer is found to separate close to the ramp corner forming a separation bubble. The streamwise length of the separa-tion bubble is found to increase with the ramp angle, with a consequent shift of the shock foot further upstream. At very small ramp angles up to 10 degrees, there is no evidence of separation, while at large ramp angles of 28 degrees, the separation bubble extends upstream to about 3.5δ(δ=boundary layer thickness). In all cases, the separation bubble is however very small in the wall normal direction, typically known to be about 0.1δ, and hence is difficult to directly measure in experiments using PIV. Shock foot measurements using PIV show that the shock has a spanwise ripple, which seems directly related to the high-and low-speed streaks in the in-coming boundary layer as recently shown by Ganapathisubramani et al. (2007). The forward-facing step configuration may be thought of as an extreme case of the compression ramp geometry, with a ramp angle of 90 degrees. This configuration has not been extensively studied, and is experimentally convenient due to the large separation bubbles formed ahead of the step. In the present work, extensive measurements of the mean and unsteady flow around this configuration have been done, especially for the case of h/δ=2, where his the step height. Pressure measurements in this case, show clear low-frequency motions of the shock at non-dimensional frequencies of about fh/U∞≈ 0.02. In this case, PIV measurements show the pres-ence of a large mean separation bubble extending to about 4hupstream and about 1hvertically. Instantaneous PIV measurements have been done in both cross-stream (streamwise and wall-normal plane) and in the span-wise (streamwise-spanwise) plane. Instantaneous cross-stream PIV mea-surements show significant variations of the shock location and angle, be-sides large variations in the recirculation region (or separation bubble), this being determined as the area having streamwise velocities less than zero. From a large set of individual PIV instantaneous fields, we can estimate the correlation of the measured shock location to both downstream effects like the area of the recirculation region, and upstream effects like the presence of high-/low-speed streaks in the oncoming boundary layer. We find that the shock location measured from data outside the boundary layer is more highly correlated to downstream effects as measured through the recircu-lation area compared to upstream effects in the boundary layer. However, we find that the shock foot within the boundary layer has ripples in the spanwise direction which are well correlated to the presence of high-/low-speed streaks in the incoming boundary layer. These spanwise ripples are however found to be small (less than one h) compared to the highly three-dimensional shape of the recirculation region with spanwise variation of the order of 3 step heights. In summary, the study shows that the separated region ahead of the step is highly three-dimensional. The shock foot within the boundary layer is found to have ripples that are well correlated to fluctuations in the in-coming boundary layer. However, we find that the large-scale nearly two-dimensional shock motions outside the boundary layer are not well cor-related to the fluctuations in the boundary layer, but are instead well cor-related with the spanwise-averaged separation bubble extent. Hence, the present results suggest that for the forward-facing step configuration, it is the downstream effect caused by the separation bubble that leads to the observed low-frequency shock motions.

Rapid mixing and spreading of supersonic jets are two important characteristics in supersonic ejectors, noise reduction in jets and fuel mixing in supersonic combustion. It helps in changing the acoustic and thermal signature in supersonic exhaust. The supersonic nozzles in most cases result in compressible mixing layers. The subsonic nozzles form incompressible mixing layers but at high Mach numbers even they form compressible mixing layers. Compressible mixing layers have been found to have much lower mixing and spreading rates than incompressible mixing layer Birch & Eggers (1972). In order to enhance the spreading and mixing of mixing layers from supersonic nozzles various active and passive methods have been deviced. Active methods include fluid injection, fluid lobes and plasma actuation. Passive methods are mostly based on modifying the nozzle geometry such that the fluid expansion is ideal or the shock cell is broken. Many nozzles with exotic shapes have been developed to obtain mixing enhancements in supersonic jets Gutmark et al. (1995). To achieve enhanced mixing an innovative nozzle named as the Elliptic Sharp Tipped Shallow (ESTS) lobed nozzle has been developed in L.H.S.R., I.I.Sc., India Rao & Jagadeesh (2014). This nozzle has a unique geometry involving elliptical lobes and sharp tips. These lobes are generated using a simple manufacturing process from the throat to the exit. This lobed and sharp tipped structure introduces stream wise vortices and azimuthal velocity components which must help in enhanced mixing and spreading. The ESTS lobed nozzle has shown mixing enhancement with 4 lobes. The spreading rate was found to be double of the reference conical nozzle. This thesis is motivated by the need to investigate the flow physics involved in the ESTS lobed nozzle. The effect of varying the number of lobes and the design Mach number of the nozzle on the mixing and spreading characteristics will be further discussed. Visualisation studies have been performed. The schlieren and planar LASER Mie scattering techniques have been used to probe the flow. Instantaneous images were taken at axial planes with the reference conical and ESTS nozzles with three, four, five and six lobes. The nozzles are for design Mach number 2.0 and 2.5. The stagnation chamber pressure was maintained to obtain over expanded, ideally expanded and under expanded flows. LASER scattering was obtained by seeding the flow with water to observe the behaviour of the primary flow. The condensation of moisture due to the cold primary flow mixing with the ambient air was exploited to scatter laser and observe the flow structures in the mixing layer. A comparison of the images of the reference conical nozzle and the ESTS lobed nozzles shows changes in the mixing layers due to the ESTS lobed nozzles. The image of the reference conical nozzle shows a distinct potential core and mixing layers all along the length of the image. For the ESTS lobed nozzles this distinction becomes unclear shortly after the nozzle exit. Thus mixing of the primary flow and ambient air is seen to be enhanced in the case of all the ESTS lobed nozzles. The flow in the case of the ESTS lobed nozzles if found to be highly non axis symmetric. The starting process of the nozzles has been visualised using time resolved schlieren. Image processing was performed on the nozzles to quantify the spread rate. The shock structure of the nozzles has been studied and found to be modified due to the lobed geometry. The level of convolution of the mixing layer due to the lobed structure has been studied using fractal analysis. The four lobed nozzle was found to have the highest spread rate and th most convoluted shear layer. Hence this nozzle was further studied using background oriented schlieren and particle image velocimetry to quantify the flow field. These experimental results have been compared with CFD simulations using the commercial software CFX5. The computations and experiments don’t match accurately but the trends match. This allows for simulations to be used as a good first approximation. The acoustic properties of a jet are dependent on the flow structure behaviour. The ESTS lobes have been found to change the flow structure. Hence the ESTS lobed nozzle was predicted to change the acoustic signature of the flow. The acoustic measurements of the flow were carried out at National Aerospace Laboratories, Bengaluru. The screech of the overexpanded flow was seen to be eliminated and the overall sound levels were found to have been reduced in all cases. Thus the lobed nozzle was found to have acoustic benefits over the reference conical nozzle. Thus the ESTS lobed nozzle has been studied and compared with the conical nozzle using several methods. The changes due to the lobed structure have been studied quantitatively. Future studies would focus on the change in thrust due to the lobed structure. Also new geometries have been proposed inspired by the current design but with possible thrust benefits or manufacturing benefits.

This work describes briefly electron microscopy issue and physical model of fluid flow. Then presented diploma thesis will be describing analysis and evaluation of the impact of supersonic flow on the pressure and density in the path of the primary electron beam in the differential pumping chamber. For analysis, evaluation and examination of the issue will be used CAD and CAE (Computer Aided Engineering) programs. At the same time it will be developed a methodology of calculation applicable to supersonic flow in the low pressure system at ANSYS CFX.

Dans ce travail de thèse, les mécanismes à l'origine de la formation des chocs associés à la perception de crackle proche de jets supersoniques axisymétriques sont étudiés à l'aide de simulations numériques. Dans ces simulations, les équations de Navier-Stokes instationnaires et compressibles sont résolues en coordonnées cylindriques à l'aide de différences finies d'ordre élevé peu dissipatives et peu dispersives. Quatre jets temporels à des nombres de Mach de 2 et~3 et à des nombres de Reynolds compris entre 3125 et 50000 sont simulés dans un premier temps. Des ondes acoustiques de forte amplitude présentant d'importants gradients de pression sont mises en évidence à proximité des jets. Elles se forment par un mécanisme de raidissement à la source qui est étudié par le calcul de moyennes conditionnelles synchronisées autour des pics de pression en champ proche. Ces moyennes montrent un lien direct entre ces ondes non linéaires et la convection de structures cohérentes à desvitesses supersoniques dans les couches de~mélange. L'influence de la température sur la formation de ces ondes est examinée dans un second temps par le calcul de cinq jets temporels à des rapports de température de 1, 2 et 4, et à des nombres de Mach acoustique compris entre 2 et 4. À vitesse d'éjection constante, les niveaux de bruit produits par les jets chauds sont moins élevés que ceux du jet isotherme, mais les ondes non linéaires qu'ils rayonnent sont peu affectées par une hausse de température. À nombre de Mach constant, les niveaux augmentent avec la température, de même que l'asymétrie des fluctuations de pression, traduisant un renforcement du caractère non linéaire des ondes rayonnées. Ces variations pourraient être dues à celles de la vitesse de convection des structures cohérentes, qui augmente de façon significative avec la température lorsque le nombre de Mach est constant, mais diminue légèrement à vitesse~constante. Finalement, trois simulations de jets spatiaux isothermes et chauds à un nombre de Mach acoustique de 2 et à des nombres de Reynolds de 12500 et 50000 sont mises en \oe uvre. Des ondes de Mach présentant d'importants gradients de pression sont visibles au voisinage direct des jets. La formation de ces ondes est liée, comme dans le cas des jets temporels, à la convection supersonique de structures cohérentes dans les couches de mélange. Le champ lointain acoustique est enfin déterminé par des méthodes d'extrapolation linéaire et non linéaire. Lorsque la propagation est non linéaire, un raidissement additionnel des fronts d'onde est constaté en champ lointain. / Numerical simulations are carried out with the aim of investigating the formation of nonlinear steepened waves at the origin of crackle in the near acoustic field of supersonic jets. In these simulations, the compressible Navier-Stokes equations are solved in cylindrical coordinates using high-order low-dissipative and low-dispersive finite difference schemes.Four temporally-developing isothermal round jets are first simulated at Mach numbers of~2 and~3 and at Reynolds numbers ranging from 3,125 to 50,000. Strong acoustic waves containing sharp pressure variations are observed in the vicinity of the jets. Their formation process is described by the computation of conditional averages which are triggered by the detection of strong pressure peaks in the near field. Such steepened waves are then shown to be produced by the supersonic motion of coherent structures inside the jet shear layers.Temperature effects are then investigated by considering five temporal round jets at temperature ratios of 1, 2 and~4 and at acoustic Mach numbers of 2, 2.8 and 4. For a given jet speed, the sound levels produced by the hot jets are lower than those of the isothermal one. However, the properties of the steepened waves they generate are not significantly affected by a rise of temperature. On the contrary, when the Mach number is held constant, pressure levels are higher at high temperature. The skewness and kurtosis factors of pressure fluctuations are also increased, which indicates a strengthening of the asymmetry and the intermittency of the pressure fluctuations. It is likely that the influence of temperature on these waves results from the variations of the convection speed, which is found to significantly increase with temperature at constant Mach number, but to slightly decrease at constant jet speed.Finally, three simulations of spatially-developing axisymmetric, isothermal and hot jets at a Mach number of~2 and at Reynolds numbers of 12500 and 50000 are performed. Strong Mach waves possessing the distinctive features of crackle are visible in the near vicinity of the jets. As observed for temporal simulations, their formations are associated with the supersonic motion of large-scale coherent structures inside the jet shear layers. The far acoustic field is determined using linear as well as nonlinear extrapolation methods. When nonlinear propagation effects are taken into account, a further steepening of the wavefronts is observed with increasing propagation distance.

This thesis is focused on electron microscopy which issue is discussed at the beginning of work. The main attention is dedicated to the Environmental electron microscope, especially the differentially pumped chamber, which the thesis deals with. There is a production of an experimental chamber for analysis of shock waves on going therefore main goal of this thesis was to analyze the flow pattern in this chamber. Using the Ansys Fluent program, simulations of the characteristic flow that arises from the pumping of the vacuum chambers namely the ultrasonic flow at low pressures on which the most suitable turbulent module was applied as well as the degree of discretization was performed. The final analysis of this flow pattern is primarily focused on the localization of the shock wave which experimental evidence is to be lodged by shadow optical method as a part of the new concept of the chamber. The basis for the simulation of the chamber was taken over by Dr. Danilatos, with which the results were compared.

<p>Micro- and nanoparticles (MNP) attract much attention owing to their unique properties, structural tunability, and wide range of practical applications. To deposit these important materials on surfaces for generating functional coatings, a variety of special delivery systems and coating/printing techniques have been explored. Herein, spray coating technique is a promising candidate to advance the field of nanotechnology due to its low-cost, high-deposition rate, manufacturing flexibility, and compatibility with roll-to-roll processing. Despite great advances, direct scalable spray writing of functional materials at high-spatial resolution through fine patterning without a need of vacuum and mask equipment still remains challenging. Addressing these limitations requires the development of efficient spray deposition techniques and novel manufacturing approaches to effectively fabricate functional coatings. To this end, this dissertation employs three different spray coating methods of (1) cold spray; (2) atomization-assisted supersonic spray, and (3) dual velocity regime spray to address the aforementioned limitations. A comprehensive set of coating materials, design principles, and operational settings for each spray system are tailored for rapid, direct, and sustainable deposition of MNP on various substrates. Besides, through the two-phase flow modeling, droplets dispersion and deposition characteristics were investigated under both subsonic and supersonic flow conditions to uncover the process-structure-property relationships of the established spray systems. Moreover, novel spray-based manufacturing approaches are developed to fabricate functional coatings in various applications, including (i) functional polymer metallization, (ii) printed flexible electronics, (iii) advanced thin-film nanocoating, (iv) laser direct writing, and (v) electronic textiles.</p>