Coating techniques are frequently used in industrial processes such as paper manufacturing, wire sleeving, and in the iron and steel industry. Depending on the application considered, the thickness of the resulting substrate is controlled by mechanical (scraper), electromagnetic (if the entrained fluid is appropriated), or hydrodynamic (gas-jet wiping) operations. This paper deals with the latter process, referred to as gas-jet wiping, in which a turbulent slot jet is used to wipe the coating film dragged by a moving substrate. This mechanism relies on the gas-jet–liquid film interaction taking place on the moving surface. The aim of this study is to compare the results obtained by a lubrication one–dimensional model, numerical volume of fluid–large eddy simulation (VOF-LES) modeling and an experimental approach. The investigation emphasizes the effect of the controlling wiping parameters, i.e., the pressure gradient and shear stress distributions induced by the jet, on the shape of the liquid film. Those profiles obtained experimentally and numerically for a jet impinging on a dry fixed surface are compared. The effect of the substrate motion and the presence of the dragged liquid film on these actuators are analyzed through numerical simulations. Good agreement is found between the film thickness profile in the wiping zone obtained from the VOF-LES simulations and with the analytical model, provided that a good model for the wiping actuators is used. The effect of the gas-jet nozzle to substrate standoff distance on the final coating thickness is analyzed; the experimental and predicted values are compared for a wide set of conditions. Finally, the occurrence of the splashing phenomenon, which is characterized by the ejection of droplets from the runback film flow at jet impingement, thus limiting the wiping process, is investigated through experiments and numerical simulations.

In the last decade, Fused Deposition Modeling (FDM) has gained popularity for allowing the fabrication of pieces with complex shapes. The final quality of the pieces is strongly linked to the shape, size and surface finish of the strands deposited successively, which themselves depend on the printing parameters and extruded material properties. In this work, we present an experimental characterization of an extruded and deposited single strand of Poly-Lactic Acid (PLA), by means of high-speed visualization of the bead region between the substrate and the nozzle, where the molten polymer is still in liquid phase. A Computational Fluid Dynamics (CFD) model proposed in literature, and, based on isothermal and viscous flow assumptions, is validated with this data in terms of strand height and meniscus shape. The characteristics of the printed layer are also confronted to the measurements of the solidified strands by microscopy, with a good agreement. The focus on high printing speeds allows extending the conclusions of previous studies. Regarding the surface finish, the roughness patterns detected on the printed strands are correlated to the velocity fluctuations of the printing head. The CFD model does not capture those thickness variations, however, due to not accounting for solidification.

Experiments in laminar flow in a rectangular channel containing a cylindrical rod have revealed a flow instability in the form of weak pulsations across the gap between the rod and the channel wall. The instability occurs when the Reynolds number reaches a critical value, which increases as the gap diminishes. As the Reynolds number is increased, the pulsations become stronger and develop, first into hairpin-shaped patterns, then into quasiperiodic laminar vortices, which alternate on either side of the gap. Eventually, the flow becomes turbulent, albeit preserving a quasiperiodic vortical structure. Within the present experimental range, the Strouhal number of the pulsations increases with increasing Reynolds number. The instability process is discussed in the context of previous analyses of low-speed streak instability of wall-bounded flows and transition to turbulence.

To increase the applications of FDM (fusion deposition modeling) 3D printing in electronics, it is necessary to develop new filaments with good electrical properties and suitable processability. In this work, polymer composites filament-shaped with superior electrical performance based on polylactic acid (PLA) carbon nanotubes and lignin blends have been studied by combining solution mixing and melt blending. The results showed that composites achieve electrical percolation from 5 wt.% of nanotubes, with high electrical conductivity. Moreover, the introduction of a plasticizing additive, lignin, improved the printability of the material while increasing its electrical conductivity (from (1.5 ± 0.9)$·$10⁻⁷ S$·$cm⁻¹ to (1.4 ± 0.9)$·$10⁻¹ S cm⁻¹ with 5 wt.% carbon nanotubes and 1 wt.% lignin) maintaining the mechanical properties of composite without additive. To validate lignin performance, its effect on PLA/MWCNT was compare with polyethylene glycol. PEG is a well-known commercial additive, and its use as dispersant and plasticizer in PLA/MWCNT composites has been proven in bibliography. PLA/MWCNT composites display easier processability by 3D printing and more adhesion between the printed layers with lignin than with PEG. In addition, the polyethylene glycol produces a plasticizing effect in the PLA matrix reducing the composite stiffness. Finally, an interactive electronic prototype was 3D printed to assess the printability of the new conducting filaments with 5 wt.% of MWCNT.

This paper presents an analysis of the gas-jet wiping process in hot-dip galvanization. This technique consists of reducing the liquid film thickness on a moving substrate by applying gas slot jets. A theoretical development allows the computation of the film thickness evolution in the wiping zone. It is further simplified to an engineering model which predicts directly the final coating thickness, in good agreement with wiping experiments. The limit of applicability of jet wiping is due to the occurence of a violent film instability, called splashing, which takes the form of a liquid droplet emission just upstream the nozzle. An experimental investigation of this phenomenon is conducted on a water-model facility. Two nozzle designs are tested. The effect of process parameters such as the strip speed, the nozzle pressure, the standoff distance, and the tilt angle of the nozzle on splashing is emphasized. A dimensionless correlation is established to predict the operating conditions leading to splashing occurence. It is successfully confronted to observations made on galvanization lines.

We analyze the flow of a planar gas jet impinging on a thin film dragged by a vertical moving wall. In the coating industry, this configuration is known as jet wiping, a process in which impinging jets control the thickness of liquid coatings on flat plates withdrawn vertically from a coating bath. We present three-dimensional (3D) two-phase flow simulations combining large eddy simulation (LES) and volume of fluid techniques. Three wiping configurations are simulated and the results are validated with experimental data from previous works. Multiscale modal analysis is used to analyze the dynamic interaction between the gas flow and the liquid film. In particular, we present a combination of multiscale Proper Orthogonal Decomposition (mPOD) and correlation analysis. The mPOD is used to identify the dominant traveling wave pattern in the liquid film flow, and the temporal structures are used to determine the most correlated flow features in the gas jet. This allows for revealing a two-dimensional mechanism for wave formation in the liquid coat. Finally, we use the numerical results to analyze the validity of some of the critical assumptions underpinning the derivation of integral film models of jet wiping.