The effect of nozzle surface features on the overall atomization behavior of a liquid jet is analyzed in the present computational work by adopting three representative geometries, namely a single X-ray tomography scan of the Engine Combustion Network’s Spray A nozzle (Unprocessed), a spline reconstruction of multiple scans (Educated), and a purely external flow configuration. The latter configuration is often used in fundamental jet atomization studies. Numerically, the two-phase flow is solved based on algebraic volume-of-fluid methodology utilizing the OpenFoam solver, interFoam. Quantitative characterization of the surface features concerning the first two geometries reveals that while both of them have similar levels of cylindrical asymmetries, the nozzle configuration pertaining to the Unprocessed geometry has much larger surface features along the streamwise direction than the Educated geometry. This produces for the Unprocessed configuration a much larger degree of non-axial velocity components in the flow exiting the orifice and also a more pronounced disturbance of the liquid surface in the first few diameters downstream of the nozzle orifice. Furthermore, this heightened level of surface destabilization generates a much shorter intact liquid core length, that is, it produces faster primary atomization. The surprising aspect of this finding is that the differences between the Unprocessed and Educated geometries are of $\mathrm{O}$ (1) μm, and they are able to produce $\mathrm{O}$ (1) mm effects in the intact liquid core length. In spite of more pronounced atomization for the Unprocessed geometry, the magnitude of the turbulent liquid kinetic energy is roughly the same as the Educated geometry. This highlights the important role of mean field quantities, in particular, non-axial velocity components, in precipitating primary atomization. At the other end of the spectrum, the external-only configuration has the mildest level of surface disturbances in the near field resulting in the longest intact liquid core length.

Spray-wall interactions directly affect fuel-air mixture preparation and emissions formation. They are therefore among the most critical physical processes in engines today. This special issue of International Journal of Engine Research presents 11 papers that investigate spray-wall interactions and their effects at both fundamental and practical levels. This brief article offers background and context for the special issue and summarizes each research paper in the collection.

The extent to which the continuum treatment holds in binary droplet collisions is examined in the present work by using a continuum-based implicit surface capturing strategy (volume-of-fluid coupled to Navier-Stokes) and a molecular dynamics methodology. The droplet pairs are arranged in a head-on-collision configuration with an initial separation distance of 5.3 nm and a velocity of 3 ${\mathrm{ms}}^{-1}$. The size of droplets ranges from 10–50 nm. Inspecting the results, the collision process can be described as consisting of two periods: a preimpact phase that ends with the initial contact of both droplets, and a postimpact phase characterized by the merging, deformation, and coalescence of the droplets. The largest difference between the continuum and molecular dynamics (MD) predictions is observed in the preimpact period, where the continuum-based viscous and pressure drag forces significantly overestimate the MD predictions. Due to large value of Knudsen number in the gas (${\text{Kn}}_{\mathrm{gas}}=1.972$), this behavior is expected. Besides the differences between continuum and MD, it is also observed that the continuum simulations do not converge for the set of grid sizes considered. This is shown to be directly related to the initial velocity profile and the minute size of the nanodroplets. For instance, for micrometer-size droplets, this numerical sensitivity is not an issue. During the postimpact period, both MD and continuum-based simulations are strikingly similar, with only a moderate difference in the peak kinetic energy recorded during the collision process. With values for the Knudsen number in the liquid (${\text{Kn}}_{\mathrm{liquid}}=0.01$ for $D=36\mathrm{nm}$) much closer to the continuum regime, this behavior is expected. The 50 nm droplet case is sufficiently large to be predicted reasonably well with the continuum treatment. However, for droplets smaller than approximately 36 nm, the departure from continuum behavior becomes noticeably pronounced, and becomes drastically different for the 10 nm droplets.