Three-dimensional simulation of micrometer-sized droplet impact and penetration into the powder bed

Experimental study of liquid drop impact on granular medium: Drop spreading/splashing and particle ejection

The impact of a liquid drop on a granular medium is a common phenomenon in nature and engineering. The possible splashing droplets and ejected particles could pose a risk of pathogen transmission if the water source or granular medium is contaminated. This work studies the liquid drop impact on the granular medium using high-speed photography and considers the effects of liquid properties, drop impact characteristics, and granular medium properties. Four flow regimes, including direct penetration, prompt splashing, spreading, and corona splashing, are observed and a regime map is created to identify their thresholds. The spreading regime can eject a large number of particles, and the corona splashing regime can produce splashing droplets in addition to the ejected particles. For the splashing droplets, their median diameters and velocities are in the ranges 0.11 to 0.21 and 0.15 to 0.37 of the diameter and velocity of the impact drop, and their median splashing angles range from 14° to 27°. Two particle ejection mechanisms are observed, falling squeeze and forward collision, driven by the collapsing and forward spreading of the liquid lamella, respectively. The particles ejected by the latter mechanism have larger ejection velocities, angles and distances from the impact center, which can facilitate their long-range transmission. In addition, the process of spreading and retracting of the lamella formed by the drop impact is also studied, and it is found that the maximum spreading diameter of the lamella is proportional to the crater diameter. These results improve the understanding of the phenomenon after the drop impact on the granular medium and the characteristics of the splashing droplets and ejected particles, contributing to the prediction and risk assessment of contaminated particle transmission.

Simulation of Binder Jetting and Analysis of Magnesium Alloy Bonding Mechanism

Binder jetting (3DP) is a kind of additive manufacturing at room temperature and atmospheric environment, which can reduce the risk of magnesium alloy forming. Magnesium alloy powder is bonded to a certain structure by a binder, so the appropriate binder is very important in 3DP. In this study, according to the characteristics of magnesium alloy, a simple and easy-to-obtain water-based low-molecular alcohol binder was used to reduce the difficulty of magnesium alloy 3DP. Additionally, we use COMSOL Multiphysics simulation software to establish a simulation model of the movement and deposition process of the binder. The results show that the increase in jet velocity will increase the quality and saturation of droplets. More importantly, the larger the jet velocity is, the larger the spreading width of the binder droplet after impacting the powder bed, which seriously affects the dimensional accuracy of the green part. In addition, lower binder saturation will weaken the formation of interparticle bonding neck and cannot form a stable structure. Furthermore, we analyzed the bond reactants of the binder and magnesium alloy powder, which eventually decompose into MgO, and the experimental results show that the final sintered sample has considerable performance.

Probing Ink-Powder Interactions during 3D Binder Jet Printing Using Time-Resolved X-ray Imaging

Capillary-driven ink infiltration through a porous powder bed in three-dimensional (3D) binder jet printing (inkjet printing onto a powder bed) controls the printing resolution and as-printed "green" strength of the resulting object. However, a full understanding of the factors controlling the kinetics of the infiltration remains incomplete. Here, high-resolution in situ synchrotron radiography provides time-resolved imaging of the penetration of an aqueous solution of eythylene glycol through a porous alumina powder bed, used as a model system. A static drop-on-demand inkjet printer was used to dispense liquid droplets onto a powder surface. The subsequent migration of the liquid front and its interactions with powder particles were tracked using fast synchrotron X-radiography in the Diamond Synchrotron, with phase-contrast imaging at a frame rate of 500 Hz. Image processing and analysis reveal that both the time-dependent increment in the wetting area and the propagation of the "interface leading edge" exhibit heterogeneous behavior in both temporal and spatial domains. However, mean infiltration kinetics are shown to be consistent with existing infiltration models based on the Washburn equation modified to account for the spreading of the liquid drop on the powder surface and using a modified term for the bed porosity.