Spray forming

In the gas/liquid spray form of nebulizer, a stream of gas interacts with a stream of liquid. Depending on the relative velocity of the two streams and their relative orientation, the liquid flow is broken down into a spray of droplets, as in the common hair sprays. 

Aerosol Shampoos. These shampoos constitute a very small percentage of the market. They have been available in two versions, ie, Hquid foam types and dry spray forms. The Hquid foam type, despite its convenience and appealing appearance, did not attain high general use. Factors involved in its low acceptabiHty include not only higher product cost but also serious stabiHty issues with can corrosion. 

Lysine vasopressin is marketed in nasal spray form as an antidiuretic under the trademark Diapid (Sando2). 

Metal injection mol ding (MIM) holds great promise for producing complex shapes in large quantities. Spray forming, a single-step gas atomization and deposition process, produces near-net shape products. In this process droplets of molten metal are coUected and soHdifted onto a substrate. Potential appHcations include tool steel end mills, superalloy tubes, and aerospace turbine disks (6,7). 

Vapor-Liquid Separation This design problem may be important for a number of reasons. The most important is usually prevention of entrainment because of value or product lost, pollution, contamination of the condensed vapor, or fouling or corrosion of the surfaces on which the vapor is condensed. Vapor-liquid separation in the vapor head may also oe important when spray forms deposits on the w ls, when vortices increase head requirements of circulating pumps, and when shoiT circuiting allows vapor or unflashed liquid to be carried back to the circulating pump ana heating element. 

Cooling of water can be carried out on a small scale either by allowing it to stand in an open pond or by the spray pond technique in which it is dispersed in spray form and then collected in a large, open pond. Cooling takes place both by the transference of sensible heat and by evaporative cooling as a result of which sensible heat in the water provides the latent heal of vaporisation. 

A sample of hops which had been treated with tetraethyl pyrophosphate showed a negative chemical analysis. The plant material was also extracted and the extract added to the drinking water of test animals and sensitive insects. The animals and insects that drank this treated water for several days showed no reaction. With the sensitive insects it would have been possible to detect even a few parts per million. In addition, there have been extensive commercial field applications of the chemical in dust and spray form to crops such as apples, pears, grapes, celery, broccoli, Brussels sprouts, and others up to within a few days of harvest there has been no detectable poison residue on any of the crops. The lack of poison residue with use of tetraethyl pyrophosphate is due to the fact that it hydrolyzes within a few hours of application, breaking down into transient nonresidual and nonpoisonous chemicals. Thus it is possible to use tetraethyl pyrophosphate well up to harvest time of food products without danger of residual poison on crops. The fact that the chemical is used in extremely small amounts is a definite advantage in respect to freedom from poison residue. 

Below 200°C, reliable urea thermohydrolysis is very hard to achieve, therefore urea dosage is usually stopped in real-world urea-SCR systems in this temperature regime. Another serious problem connected with the urea injection at low temperatures is the formation of white to yellowish deposits, which are observed when urea solution is injected at very low exhaust gas temperatures or if the urea spray forms a thick film at the walls of the SCR system. The analysis of these deposits [26] showed that they mainly consist of urea and some biuret at low temperatures and of cyanuric acid and some biuret at higher exhaust gas temperatures around 350°C. From laboratory investigations of the urea decomposition, it is known that biuret is easily formed from 150 to 190°C [27], whereas the formation of cyanuric acid is predominant from 200 to 300°C, according to the following reactions [12] ... 

Spray-forming, of particulate metal-matrix composites, 16 175 Spray functions, 23 174t Spray impact, 23 197 measurements, 23 194-195 Spraying processes, for sodium carbonate peroxohydrate, 18 412 Spraying techniques, in fluidized-bed encapsulation, 11 541-542 Spray instrumentation, 23 192-195 Spray irrigation... 

Spray Deposition Net or Near-Net Shape Manufacturing - Spray Forming - Spray Casting - Spray Rolling... 

Atomization of melts has been used in two principal areas, i.e., powder production 4] and spray forming, 3] as shown in Figs. 1.4 and 1.5, respectively. It is not until recent years that the technologies for the atomization of melts have advanced sufficiently to ensure good yields of usable products over sustained periods of plant operation. In these two areas, some aspects such as melting of metals or alloys, basic atomizer designs, and atomization mechanisms are the same or similar. Metals or alloys melt at high temperatures to produce low viscosity but usually... 

Figure 1.5. (a) Schematic of spray forming process (b) a pilot-plant scale facility for spray forming at University of Bremen, Germany. Top top view. Bottom side view (Courtesy of Prof. Dr.-Ing. Klaus Bauckhage at University of Bremen, Germany.)... 

Figure 1.6. Size ranges of droplets/particles found in nature and generated by atomization of normal liquids and melts in aerosol spray, spray combustion, powder production, and spray forming processes.

Figure 1.7. Shapes of solidified droplets (particles) generated in powder production and spray forming processes, (a) Spherical shape gas-atomized gold alloy particles (b) near-spherical and dendritic shapes water-atomized bronze particles (c) irregular and porous (spongiform) shapes water-atomized zinc particles (d) irregular aggregates water-atomized copper particles (Cour. tesy of Atomizing Systems Ltd., UK.)...

Numerous atomization techniques have evolved for the production of metal/alloy powders or as a step in spray forming processes. Atomization of melts may be achieved by a variety of means such as aerodynamic, hydrodynamic, mechanical, ultrasonic, electrostatic, electromagnetic, or pressure effect, or a combination of some of these effects. Some of the atomization techniques have been extensively developed and applied to commercial productions, including (a) two-fluid atomization using gas, water, or oil (i.e., gas atomization, water atomization, oil atomization), (b) vacuum atomization, and (c) rotating electrode atomization. Two-fluid atomization... 

Droplet Formation in Gas Atomization. Experimental and modeling studiesl160 161 169] 318] 319] 321]- 325] have shown that gas atomization of liquid metals in spray forming and powder metallurgy processes may take place in two primary modes, i.e., liquid jet-ligament breakup and liquid film-sheet breakup. 

It should be noted that the dynamic conditions of droplet impact processes discussed above cover a large range of the actual conditions in many industrial processes, such as spray forming, thermal spray, spray combustion, spray cooling, and aircraft flight. Under these conditions, the spreading behavior of droplets on a flat surface is essentially governed by inertia and viscous effects (Fig. 

As for normal liquids, modeling of droplet processes of melts provides tremendous opportunities to improve the understanding of the fundamental phenomena and underlying physics in the processes. It also provides basic guidelines for optimization and on-line control of the processes. This section is devoted to a comprehensive review of process models, computational methods, and numerical modeling results of the droplet processes of melts. The emphasis of this section will be placed on the droplet processes in spray atomization for metal powder production, and spray forming for near-net shape materials synthesis and manufacturing. Details of these processes have been described in Ref. 3. 

Over the past decade, a number of numerical studies have been performed to model the liquid metal and gas delivery, spray, deposition, and consolidation stages in spray forming. 18] 51 52] 154] 156] 174] 338]... 

In some spray forming processes, the atomization gas exits the atomizer nozzle(s) at sonic or supersonic velocities. The gas may expand... 

The modeling results of the spray stage provide input data and initial conditions for the modeling of droplet-substrate interactions in the ensuing deposition stage of the spray forming process. 

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