Additive manufacturing is a growing field dominated by printing processes that soften and re-solidify material, depositing this material layer by layer to form the printed shape. Increasingly, researchers are pursuing new materials to enable fabrication of a wider variety of associated capabilities. This includes fabrication with high-viscosity materials of many new classes of material compositions, such as doping for magnetic or electrically conducting polymers. These additives complicate the materials deposition process by requiring complex, non-linear calibration to synchronize these new candidate materials with the additive manufacturing software and hardware. In essence, additive manufacturing is highly dependent on identifying the delicate balance between materials properties, hardware, and software-which is currently realized via a time-consuming and costly iterative calibration process. This thesis is concerned with reducing this cost of calibration, in particular by providing a time-based metric based on material viscosity for material retraction at the conclusion of each extrusion. It presents a novel non-contact method of determining the material retraction rate (during reversal of extrusion), by measuring the variation in laser intensity resulting from the deformation of the material reservoir due to change in material pressure. Commercially available laser measurement systems cost more than $20,000 and are limited to 1 μm at a 300 ms (3 Hz) sampling rate. The experimental setup presented in this thesis costs less than $100 and is capable of taking measurements of 1 - 2 μm at a 0.535 ms (1870 Hz) sampling rate. For comparison, the stepper motor driving the material extruder operates at 0.667 ms (1500 Hz). Using this experimental setup, an inverse correlation is shown to exist between the viscosity of a material and the rate at which the material is retracted. Using this correlation and a simplified material analysis process, one can approximate the retraction time necessary to calibrate new materials, thereby significantly improving initial estimated calibration settings, and thus reducing the number of calibration iterations required to ready a new material for additive manufacturing. In addition, the insight provided into the material response can also be used as the basis for future research into minimizing the calibration process. / Master of Science / Additive manufacturing is a growing field with an ever-expanding base of materials used in the printing process. Two types of material gaining popularity in the commercial and academic communities are pastes and liquids. These materials require a different method of printing, and users need to take into account other considerations, such as viscosity and pressure, for their precise control. Traditionally, a new material would require a time consuming or costly calibration process to properly print. To decrease the investment required for calibration, this thesis presents a new non-contact method of measuring the pressure of the liquids using a laser to detect a dimensional change in the size of the container. This measurement technique enables an initial calibration estimate that is closer to the optimal setting, potentially allowing for better printing results when working with new materials for additive manufacturing.

Drop-on-demand (DOD) inkjet print-head has a major share of the market due to simplicity and feasibility of miniature system. The efficiency of droplet generation from DOD print-head is a result of several factors, include viscosity, surface tension, nozzle size, density, driving waveform (wave shape, frequency, and amplitude), etc. Key roles in the formation and behavior of liquid jets and drops combine three dimensionless groups: Reynolds number, Weber number and Ohnesorge number. These dimensionless groups provide some bounds to the “printability” of the liquid. Adequate understanding of these parameters is essential to improve the quality of droplets and provide guidelines for the process optimization. This thesis research describes the application of computational fluid dynamics (CFD) to simulate the creation and evolution process of droplet generation and transport of a highly viscous Newtonian fluid. The flow field is governed by unsteady Navier-Stokes equations. Volume of Fluid (VOF) model is used to solve this multi-phase (liquid-gas) problem.

A study on high-viscosity oil-water flow in horizontal pipes has been conducted applying experimental, mechanism analysis and empirical modelling, and CFD simulation approaches. A horizontal 1 inch flow loop was modified by adding a designed sampling section to achieve water holdup measurement. Experiments on high-viscosity oil-water flow were conducted. Apart from the data obtained in the present experiments, raw data from previous experiments conducted in the same research group was collated. From the experimental investigation, it is found that that the relationship between the water holdup of water-lubricated flow and input water volume fraction is closely related to the oil core concentricity and oil fouling on the pipe wall. The water holdup is higher than the input water volume fraction only when the oil core is about concentric. The pressure gradient of water-lubricated flow can be one to two orders of magnitude higher than that of single water flow. This increased frictional loss is closely related to oil fouling on the pipe wall. Mechanism analysis and empirical modelling of oil-water flow were conducted. The ratio of the gravitational force to viscous force was proposed to characterise liquid-liquid flows in horizontal pipes into gravitational force dominant, viscous force dominant and gravitational force and viscous force comparable flow featured with different basic flow regimes. For viscous force dominant flow, an empirical criterion on the formation of stable water-lubricated flow was proposed. Existing empirical and mechanistic models for the prediction of water holdup and/or pressure gradient were evaluated with the experimental data; the applicability of different models is demonstrated. Three-dimensional CFD modelling of oil-water flow was performed using the commercial CFD code Fluent. The phase configurations calculated from the CFD model show a fair agreement with those from experiments and mechanism analysis. The velocity distribution of core annular flow is characterised with nearly constant velocity across the oil core when the oil viscosity is significantly higher than the water viscosity, indicating that the high-viscosity oil core flows inside the water as a solid body. The velocity profile becomes similar to that of single phase flow as the oil viscosity becomes close to the water viscosity.

Drop impacts are present in our everyday lives, from showering and washing the dishes to inkjet printing and many industrial processes, such as spray coatings and spray cooling. In many of these applications it may be undesirable to have air entrained within the drop when it impacts a surface. As a drop approaches a surface, the gas beneath the drop is unable to fully escape resulting in a rising pressure which becomes sufficient to form a dimple in the bottom center of the drop. Therefore, when the drop makes contact with the surface, it is around the perimeter of this dimple, thus entrapping a disc of air which contracts into a minute bubble. In this dissertation, we study the very early time dynamics of the formation of the central air disc under a variety of circumstances using ultra-high-speed interferometry at rates up to 5 million frames per second. We show the effects of the liquid viscosity for viscosities spanning 7 orders of magnitude, for impacts of drops onto solid surfaces or a film of the same liquid. We find that the size of the air disc is weakly dependent on the drop viscosity to the -1/9 power. We also explore the extended gliding of the drop on a less than 160 nm thick film of air. For impacts onto a solid surface, this gliding layer is rupture in multiple random locations and each localized contact wets the surface at extreme rates compared with the expected viscous-capillary velocity. For impacts onto liquid films, the localized contacts are rarely observed and the gliding layer ruptures at a uniform location. The central bubble contracts much faster than expected in this case as well. Furthermore, we study the effects of reducing the ambient air pressure discovering a compressible and rarified-gas regime wherein the drop makes a double contact with the surface. Lastly, we study the effects of nano-scale surface roughness on the central bubble and the formation of thick bands of microbubbles around the periphery of the air disc.

Heavy oil production has drawn more and more attention in petroleum industry. The amount of heavy oil in the world is twice more than the conventional oil (low viscosity), which has been consumed rapidly from the past. The understanding of flow patterns and pressure losses in multiphase flow with high viscosity oil are vital to assist the design of transportation pipeline. This thesis involves experimental investigation of two phase and three phase flows under high oil viscosity conditions (up to 17000cP) in horizontal pipelines. The multiphase (oil/water/solid/gas) facility was designed and constructed at Cranfield University and consists of 6m long horizontal pipeline of 0.026m diameter along with instrumentations. The principal objectives of the work were to study the effect of viscosity, water cut, temperature variance, and flow conditions on flow patterns and pressure drops for (oil/gas and oil/water) two phase flows; to compare the measured flow parameters and phase distribution with those predicted from models found in the literature for two phase flows; and to conduct an experimental study of gas injection effect on pressure gradient in (oil/water/gas) three phase flow. Due to the nature of heavy oil reservoirs, sand is associated with oil/water mixture when extracted; therefore sand concentration effect on pressure drop in (oil/water/sand) three phase flow is also examined. For oil-air flow, a smooth oil coating was observed in the film region of slug flow, while a ripple structure of oil coating film was found at higher superficial air velocity for slug flow regime and annular flow regime. The ripple structure was believed to increase the effective roughness of the pipe wall, which resulted in higher pressure gradients. The pressure drop correlations from Beggs and Brill (1973) and Dukler et al. (1964) were used to compare with experimental pressure gradients for oil/air flow. It was found that these correlations failed to predict the pressure gradients for heavy oil/air flows in this work. Several new heavy oil/water flow patterns were named and categorized based on observations. Though the heavy oil viscosity is an essential parameter for oil continuous phase flow on pressure drop, it had no significant effect beyond Water Assist Flow (WAF) condition, as a threshold was found for water cut with fixed superficial oil velocity. The transition criterion by McKibben et al. (2000b) for WAF was found to be able to predict this threshold reasonably well. Core Annular Flow (CAF) models were found to greatly under predict the pressure gradients mainly due to the coating (oil fouling) effect associated with this study. A new coating coefficient was introduced to models presented by Bannwart (2001) and Rodriguez et al (2009). The addition of solid in the mixed flow led to minor increase in the pressure gradient when the particles were moving with the flow. However, higher sand concentration in the system led to higher pressure gradient values. The addition of gaseous phase to the oil/water flow was more complex. The gaseous injection was beneficial toward reducing the pressure gradient when introduced in oil continuous phase only at very low water cuts.

Defect generation and propagation in thin films, such as separation membranes, can lead to premature or catastrophic failure of devices such as polymer electrolyte membrane fuel cells (PEMFC). It is hypothesized that defects (e.g., air bubbles, pin-holes, and holes) originate during the manufacturing stage, if precise control is not maintained over the coating process, and they propagate during system operation. Experimental and numerical studies were performed to detect and eliminate defects that were induced during slot die coating of high-viscosity (1 to 40 Pa-s), shear-thinning solutions. The effects of fluid properties, geometric parameters and processing conditions on air entrainment and coating windows (limited set of processing conditions for which defect-free coating exists) were studied. When smaller slot gaps and coating gaps were used, relatively small bubbles were entrained in the coated film. The air bubble sizes increased as the viscosity of the coating solution decreased. A semi-empirical model correlating the maximum coating speed to a solution's material properties, geometric parameters and processing conditions was developed. Such a predictive model will enable engineers to determine the maximum coating boundary for shear-thinning and Newtonian solutions within certain constraints. Smaller coating gaps and low-viscosity solutions produced higher coating speeds. The surface tension property of the coating solution provided stability to the coating bead. Therefore, solutions with higher surface tension could be processed at higher coating speeds.

Biohybrid micromotors propelled by motile cells are fascinating entities for autonomous biomedical operations on the microscale. Their operation under physiological conditions, including highly viscous environments, is an essential prerequisite to be translated to in vivo settings. In this work, a sperm-driven microswimmer, referred to as a spermbot, is demonstrated to operate in oviduct fluid in vitro. The viscoelastic properties of bovine oviduct fluid (BOF), one of the fluids that sperm cells encounter on their way to the oocyte, are first characterized using passive microrheology. This allows to design an artificial oviduct fluid to match the rheological properties of oviduct fluid for further experiments. Sperm motion is analyzed and it is confirmed that kinetic parameters match in real and artificial oviduct fluids, respectively. It is demonstrated that sperm cells can efficiently couple to magnetic microtubes and propel them forward in media of different viscosities and in BOF. The flagellar beat pattern of coupled as well as of free sperm cells is investigated, revealing an alteration on the regular flagellar beat, presenting an on–off behavior caused by the additional load of the microtube. Finally, a new microcap design is proposed to improve the overall performance of the spermbot in complex biofluids.

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.