Search Results (16)

In ultra-precision polishing tests, due to the corrosive and adhesive properties of the polishing abrasive, the spray system faces wear, blockage and oxidation problems. To solve these problems, this paper studied nozzles and verified the wear mechanism of the coated and uncoated nozzles by simulating the operating conditions after assembling the spray system. In the early stages of the experiment, the polishing speed of the spray system (v = 10 L/min), the feed rate (v_f = 7.8 mm/min) and the polishing pressure (2~3.5 MPa) were maintained. The wear mechanism and surface morphology features of the nozzles in each case were analyzed by Hitachi S-3400N electron microscopy. When comparing the surface morphology of the nozzle coated with titanium alloy and the uncoated one, the results show that there is a significant difference in the corrosion resistance of the coatings to the abrasive particles. A significant effect was seen on the wear morphology, proving that the nozzle wear mechanism includes wear, adhesion and diffusion. Under the experimental conditions of a lateral velocity of 7.8 mm/min and a polishing force of 2 MPa, BK7 was polished using nozzles 1 and 2, resulting in a surface roughness of 75 nm and 35 nm while PV values were 125 nm and 67 nm, respectively. The excellent quality of nozzle 2 (coating nozzle) was proven, further demonstrating the superiority of the coating nozzle. Finally, the lifespan of the nozzle was extended and the surface accuracy of BK7 was improved by coating titanium alloy composite material on the 304 stainless steel nozzle. Full article

Additive Manufacturing (AM), commonly known as 3D printing, has gained significant traction across various industries due to its versatility and customization potential. However, the process remains time-consuming, with print durations ranging from hours to days depending on the complexity and size of the object. In many cases, errors occur due to object misalignment, material stringing due to nozzle overflow, and filament blockages, which can lead to complete print failures. Such errors often go undetected for extended periods, resulting in substantial losses of time and material. This study explores the implementation of traditional computer vision, image processing, and machine learning techniques to enable real-time error detection, specifically focusing on stringing-related anomalies. To address data scarcity in training machine learning models, we also release a new dataset and improve upon the results achieved by the Obico server model, one of the most prominent tools for stringing detection. Our contributions aim to enhance process reliability, reduce material wastage, and optimize time efficiency in AM workflows. Full article

The water jet nozzle is a penetrating drilling tool, which sends the pumped water to the nozzle through a high-pressure hose. It can work in a variety of working environments. When it dredges the blockage in the pipeline, its structural parameters will affect the jet flow field in the pipeline. Taking the self-propelled water jet nozzle as the research object, SolidWorks was used to establish the nozzle model with different parameter structures. Based on Fluent, the k-ε turbulence model was used to simulate the jet of nozzles with different nozzle sizes and arrangements in the pipeline. The distribution of the jet flow field and the change in velocity and displacement of nozzles with different parameters in the pipeline were compared, and then computational fluid dynamics (CFD) were used to process the simulation data for further research. The results show that when the inclination angle of the rear nozzle is 35°, the attenuation of the front jet velocity and the fluctuation of the wall fluid velocity are the smallest. When the nozzle aperture is increased from 2 mm to 3.5 mm, the vortex area inside the pipe is reduced, and the velocity attenuation of the front jet is also reduced, with the velocity attenuation rate decreasing by about 10%. This study provides a reference for the design and parameter optimization of self-propelled water jet nozzles. Full article

In order to improve the cleanliness of steel, non-aluminum deoxidation processes have begun to replace aluminum deoxidation processes. Although the aluminum deoxidation process can reduce the oxygen content in steel to <10 × 10⁻⁶, this deoxidation method causes fatigue failure resulting from the formation of large-grained spherical (Ds-type) inclusions composed of calcium–aluminate. It also tends to lead to nozzle blockage during casting. Given the above problems, this study conducted an in-depth investigation of silicon–manganese deoxidation. Thermal experiments and thermodynamic calculations were used to assess the impact of different Mn–Si ratios on the oxygen content and inclusion characteristics during the deoxidation process of molten steel with different initial oxygen contents. The experimental samples were analyzed using an oxygen–nitrogen–hydrogen analyzer, a direct reading spectrometer, and an automatic scanning electron microscope. After that, the samples were electrolyzed to observe the 2D morphology and 3D morphology of the inclusions using scanning electron microscopy. Finally, thermodynamic calculations were carried out using FactSage to verify the experimental results. The results indicated that, regardless of the initial oxygen content, silicon–manganese deoxidation maintained the total oxygen content at 35 × 10⁻⁶. It effectively managed the plasticization of inclusions in molten steel, predominantly yielding spherical silicates while minimizing Al-containing inclusions. Nevertheless, as the initial content of [O] increased, the size and density of the silicate inclusions in the steel also increased. An optimal point in the number and size of inclusions was observed with an increased Mn–Si ratio. Moreover, the combined utilization of silicon–manganese deoxidation, diffusion deoxidation, and vacuum deoxidation enabled ultra-low oxygen content control of molten steel. Full article

The airflow velocity in some nozzles is low, and the clearing of the nozzle is ineffective because of unreasonable airflow pipe arrangements and the distance from the nozzle to the screen surface of screen-hole-clearing devices for trommel-sieve-type residual film–impurity wind separators. In the present study, the main structure and working parameters affecting the screen hole clogging situation were determined through theoretical analysis and computational fluid dynamics simulations. In addition, a three-factor, three-level quadratic regression orthogonal center of rotation combination test was performed. The distance from the nozzle to the screen surface, fan wind speed, and the number of airflow pipes were selected as test factors, and the ratio of impurities in the residual film and the blockage ratio of the screen holes were selected as the evaluation indexes. The results indicated that the ratio of impurities in the residual film was reduced by 2.42% and the blockage ratio of the screen holes was reduced by 1.92% at a nozzle-to-screen distance of 102 mm, a fan wind speed of 24 m/s, and with four air pipes. The resulting impurity ratio in the film was 5.86%, and the blockage ratio of screen pores was 5.41%. The minimum airflow velocity of 15.8 m/s at each nozzle position of the optimized screen-hole-clearing device satisfied the requirements of screen hole clearing and blockage. Furthermore, the ratio of impurities in the residual film and the blockage ratio of the screen holes remained unchanged during the continuous operation of the device. This indicated that the optimized screen-hole-clearing device had a stable working performance. This study may provide a theoretical framework for the future development of screen-hole--clearing devices. Full article

The flow and dispersion characteristics of the fire extinguishing agent in the pipings and the concentration distribution in the nacelle are essential for optimizing the aircraft fire extinguishing system. In the present work, we developed a three-dimensional CFD model to simulate the transport and dispersion of the agent in piping and nacelle. The results show that the length and structure of the pipings near the nozzles affect the concentration, pressure, flow rate, and flow distribution of the extinguishing agent. The smaller the bend of the pipings near the nozzles and the angle of connection with the main piping, the less time it takes for the agent to reach the nozzles and the more mass flow rate of the agent is injected, which is more conducive to extinguishing fire rapidly. External ventilation and the blockage of the nacelle’s ribs and other components impact the concentration distribution of the fire extinguishing agent in the nacelle. The agent is mainly concentrated in the middle and rear areas of the engine nacelle. Agent concentration tests were carried out in the simulated engine nacelle. The experimental result is similar to the simulation result, which verifies the feasibility of the simulation method. The simulation method can be used to increase the concentration of fire extinguishing agent to meet the safety requirements by changing the outside ventilation and increasing the filling amount of fire extinguishing agent, so as to achieve the optimization of the fire extinguishing system. Full article

The effects of nozzle shape modifications on the flow phenomena and heat transfer characteristics in annular jet impingement are investigated numerically. The numerical simulations are conducted applying the shear stress transport (SST) $k-\omega$ model in the ANSYS CFX. Two modified nozzles: the converging nozzle and the diverging nozzle, are investigated in this study, and the straight nozzle serves as the base case. The geometric parameters and settings are based on an annular jet ejected from an axial fan used for electronic cooling: the Reynolds number $Re=$ 20,000 and the blockage ratio $Br=0.35$ in the computation, and the target plate is placed at three representative separation distances: $H=0.5,2$, and 4. Compared with the base nozzle, the converging nozzle can accelerate the cooling flow and promote turbulence to enhance local and overall heat transfer (about $20\%$) over the target surface. In addition, the converging nozzle reduces the sizes of the recirculation zones, and this promotes the convective heat transfer transport near the axis. The diverging nozzle experiences a similar flow pattern and thermal field as the base nozzle, while the diverging nozzle achieves a slightly lower heat transfer with a pronounced pressure drop reduction. In addition, given that the value of the Nusselt number over the target plate is dependent on the Reynolds number, the simulations are also performed at $Re=5000$ and 40,000 to establish the correlations between the Nusselt number and the Reynolds number as $Nu\propto R{e}^m$. The value of m varies depending on the nozzle shapes and the separation distances. Full article

The development of flexible transparent conductive electrodes has been considered as a key issue in realizing flexible functional electronics. Inkjet printing provides a new opportunity for the manufacture of FFE due to simple process, cost-effective, environmental friendliness, and digital method to circuit pattern. However, obtaining high concentration of inkjet- printed silver nanowires (AgNWs) conductive ink is a great challenge because the high aspect ratio of AgNWs makes it easy to block the jetting nozzle. This study provides an inkjet printing AgNWs conductive ink with low viscosity and high concentration of AgNWs and good printing applicability, especially without nozzle blockage after printing for more than 4 h. We discussed the effects of the components of the ink on surface tension, viscosity, contact angle as well as droplet spreading behavior. Under the optimized process and formulation of ink, flexible transparent conductive electrode with a sheet resistance of 32 Ω·sq⁻¹–291 nm·sq⁻¹ and a transmittancy at 550 nm of 72.5–86.3% is achieved. We investigated the relationship between the printing layer and the sheet resistance and the stability of the sheet resistance under a bending test as well as the infrared thermal response of the AgNWs–based flexible transparent conductive electrode. We successfully printed the coupling electrodes and demonstrated the excellent potential of inkjet-printed AgNWs—based flexible transparent conductive electrode for developing flexible functional electronics. Full article

In rice–wheat rotation areas of China, traditional wheat seeders have severe blockage, low working efficiency and poor seeding quality. In this study, a pneumatic shooting technology was designed, consisting mainly of a nozzle, shell and acceleration tube. To improve the sowing depth of the pneumatic shooting device, the response-surface methodology of structure parameters and CFD simulation technology was adopted in this work. The effects of working pressure, acceleration-tube diameter and throat distance on the steady airflow length (SAL) and steady airflow velocity (SAV) were studied by airflow field analysis, and the response-surface method was introduced to obtain the optimal parameter combination of the pneumatic shooting device for wheat. The optimal parameter combination was working pressure 686 kPa, acceleration tube diameter 8 mm and throat distance 20 mm. The simulation result showed that the optimized device of pneumatic shooting performs faster and has more stable airflow field characteristics in comparison to the initial device. The field test demonstrated that the optimized device has about 68% higher seeding depth than the initial device. The average field-seeding depth of the optimized device was 19.95 mm, which is about 68% higher than the initial device. The emergence rate for the optimized device was about 88.7% without obvious reduction. CFD and response-surface methods positively affect the optimization of pneumatic wheat-shooting devices, and the significance was also confirmed. Full article

The standard production route for mild steels for automotive purposes is still based on conventional continuous casting (CC) and hot strip rolling (HSR). The current trend towards the “zero-carbon car” will demand the abating of material emissions in the future. Thin slab casting and direct rolling (e.g., Arvedi endless strip production (ESP)) is an approach to reduce CO₂ emissions by 50% compared to CC and HSR. One of the main limitations in applying ESP for the production of ultra-low carbon/interstitial free (ULC/IF) steels is clogging. Clogging is the blockage of the submerged entry nozzle due to the build-up of oxide layers or an oxide network. The high clogging sensitivity of IF steels results most probably from the FeTi addition, and hence, a general change of the deoxidation practice might be an option to overcome these problems. In the present work, the thorough refining process of ULC steel was simulated by addressing the different deoxidation routes and the influence of titanium (Ti) alloying on steel cleanness. The developed ladle furnace (LF) and the Ruhrstahl Heraeus (RH) refining models were applied to perform the simulation. Before the simulations, the models are briefly described and validated by the published industrial data. Full article

This review article focuses on the near-field flow characteristics of coaxial circular jets that, despite their common usage in combustion processes, are still not well understood. In particular, changes in outer to inner jet velocity ratios, $r_u$, absolute jet exit velocities and the nozzle dimensions and geometry have a profound effect on the near-field flow that is characterized by shear as well as wake instabilities. This review starts by presenting the set of equations governing the flow field and, in particular, the importance of the Reynolds stress distributions on the static pressure distribution is emphasized. Next, the literature that has led to the current stage of knowledge on coaxial jet flows is presented. Based on this literature review, several regions in the near-field (based on $r_u$) are identified in which the inner mixing layer is either governed by shear or wake instabilities. The latter become dominant when $r_u\approx 1$. For coaxial jets issued into a quiescent surrounding, shear instabilities of the annular (outer) jet are always present and ultimately govern the flow field in the far-field. We briefly discuss the effect of nozzle geometry by comparing the flow field in studies that used a blockage disk to those that employed thick inner nozzle lip thickness. Similarities and differences are discussed. While impinging coaxial jets have not been investigated much, we argue in this review that the rich flow dynamics in the near-field of the coaxial jet might be put to an advantage in fine-tuning coaxial jets impinging onto surfaces for specific heat and mass transfer applications. Several open questions are discussed at the end of this review. Full article

This work attempts to connect internal flow to the exit flow and supersonic jet mixing in rectangular nozzles with low to high aspect ratios (AR). A series of low and high aspect ratio rectangular nozzles (design Mach number = 1.5) with sharp throats are numerically investigated using steady state Reynolds-averaged Navier−Stokes (RANS) computational fluid dynamics (CFD) with k-omega shear stress transport (SST) turbulence model. The numerical shadowgraph reveals stronger shocks at low ARs which become weaker with increasing AR due to less flow turning at the throat. Stronger shocks cause more aggressive gradients in the boundary layer resulting in higher wall shear stresses at the throat for low ARs. The boundary layer becomes thick at low ARs creating more aerodynamic blockage. The boundary layer exiting the nozzle transforms into a shear layer and grows thicker in the high AR nozzle with a smaller potential core length. The variation in the boundary layer growth on the minor and major axis is explained and its growth downstream the throat has a significant role in nozzle exit flow characteristics. The loss mechanism throughout the flow is shown as the entropy generated due to viscous dissipation and accounts for supersonic jet mixing. Axis switching phenomenon is also addressed by analyzing the streamwise vorticity fields at various locations downstream from the nozzle exit. Full article

This work explores the extent of jet mixing for a supersonic jet coming out of a Mach 1.8 convergent-divergent nozzle, controlled with two short rectangular vortex-generating actuators located diametrically opposite to each other with an emphasis on numerical methodology. The blockage ratio offered by the tabs is around 0.05. The numerical investigations were carried out by using a commercial computational fluid dynamics (CFD) package and all the simulations were performed by employing steady Reynolds-averaged Navier–Stokes equations and shear-stress transport $k-\omega$ turbulence model on a three-dimensional computational space for more accuracy. The numerical calculations are administered at nozzle pressure ratios (NPRs) of 4, 5, 6, 7 and 8, covering the overexpanded, the correctly expanded and the underexpanded conditions. The centerline pressure decay and the pressure profiles are plotted for both uncontrolled and the controlled jets. Numerical schlieren images are used to capture the barrel shock, the expansion fans and the Mach waves present in the flow field. Mach contours are also delineated at varying NPRs indicating the number of shock cells, their length and the variation of the shock cell structure and strength, to substantiate the prominent findings. The outcomes of this research are observed to be in sensible concurrence with the demonstrated exploratory findings. A reduction in the jet core length of 75% is attained with small vortex-generating actuators, compared to an uncontrolled jet, corresponding to nozzle pressure ratio 5. It was also seen that the controlled jet gets bifurcated downstream of the nozzle exit at a distance of about 5 D, where D is the nozzle exit diameter. Furthermore, it was fascinating to observe that the jet spread increases downstream of the nozzle exit for the controlled jet, as compared to the uncontrolled jet at any given NPR. Full article

The continuous casting process (CCP) is the most vital part of steelmaking. The flow pattern near the submerged entry nozzle (SEN) and mould greatly influence the quality of the slab produced. The present investigation was carried out to gain knowledge regarding the meniscus fluctuation under different nozzle port blockage conditions by water model experiments. The experiments were carried out to study the effect of no blockage, 25% blockage, 50% blockage, and 75% blockage of the nozzle port on mould-level fluctuations. The result shows that when the liquid flow rate increases, the wave amplitude increases. In these experiments, the average and maximum meniscus fluctuations were measured while changing different variables such as the water flow rate, gas flow rate, and one-side percentage blockage of the SEN port while the other side was fully open. The observation shows that when the port size decreases, the fluid steel mixed from the obstructing side to the open side results in asymmetry. The average and maximum wave amplitude increases with decreasing submergence depth. It was observed that the maximum height of the standing waves in the mould continued rising on the non-blocked side of the SEN. Blockage increases from 25% to 75%, and with 75% blockage of the right side of the SEN port, the mould-level fluctuation at the left side of the mould was extreme, while that of the right side was relatively quiet. Full article

In this paper, a new bell-type air nozzle, which overcomes the structural defects of traditional bell-type air nozzles, is proposed and validated by cold test and numerical simulation. The pressure drop characteristic of the new bell-type air nozzle is measured. Furthermore, the causes of cover outlet abrasion and blockage, inner tube fracture, and irregular resistance change in traditional bell-type air nozzles applied in circulating fluidized bed (CFB) boilers are analyzed. Then, the performance of the new bell-type air nozzle is evaluated in a real CFB boiler, which is operated under regular working conditions. The results show that the new bell-type air nozzle has stronger anti-wear ability, excellent resistance characteristics, longer service life, and easier maintenance. Full article