A combined numerical and experimental study to elucidate primary breakup dynamics in liquid metal droplet-on-demand printing

Beck, Victor A.; Watkins, Nicholas N.; Ashby, Ava S.; Martin, Aiden A.; Paul, Phillip H.; Jeffries, Jason R.; Pascall, Andrew J.

doi:10.1063/5.0029438

Title: A combined numerical and experimental study to elucidate primary breakup dynamics in liquid metal droplet-on-demand printing

Journal Article · Wed Nov 25 00:00:00 EST 2020 · Physics of Fluids

DOI:https://doi.org/10.1063/5.0029438· OSTI ID:1809163

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Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Droplet-on-demand liquid metal jetting is emerging as a powerful technology for the additive manufacturing of metallic parts. The success of this method hinges on overcoming several technological challenges. Additionally, the principal one among these challenges is the controlled repeatable ejection of single uniform droplets. Due to the high density and surface tension of liquid metals, the droplet ejection process occurs near the minimal extremes of the printability phase diagram, defined by acceptable ranges for the Weber (We) and Ohnesorge (Oh) numbers. In this work, we experimentally demonstrate the satellite-free ejection of pneumatically actuated molten tin droplets in this extreme corner of printability and use a combination of high-speed video analysis and volume-of-fluid modeling to elucidate the droplet dynamics. While the simulations at low Oh and We can correctly describe several aspects of the breakup process, such as an increasing tail and pinch-point near the nozzle, no single parameter set can completely capture the droplet shape at breakup. Instead, the experimental droplet dynamics appear to include features from both high and low Oh breakup. This disagreement is ascribed to the incomplete description of the droplet ejection process including wetting and exit effects near the nozzle opening and surface effects such as transient cooling and oxide formation.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA); USDOE Laboratory Directed Research and Development (LDRD) Program

Grant/Contract Number:: AC52-07NA27344; AC52-07-NA27344; 18-SI-001

OSTI ID:: 1809163

Alternate ID(s):: OSTI ID: 1724248

Report Number(s):: LLNL-JRNL-814299; 1022740; TRN: US2213144

Journal Information:: Physics of Fluids, Vol. 32, Issue 11; ISSN 1070-6631

Publisher:: American Institute of Physics (AIP)Copyright Statement

Country of Publication:: United States

Language:: English

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Title: A combined numerical and experimental study to elucidate primary breakup dynamics in liquid metal droplet-on-demand printing

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