Numerical simulation and experimental analysis of aerosol deposition: Investigating nozzle effects on particle dynamics and deposition

Aerosol deposition (AD), also known as vacuum kinetic spray (VKS), is used to deposit dense ceramic films onto a substrate surface at room temperature. One predominant factor influencing the overall deposition process is the nozzle geometry, which significantly impacts the quality, shape, and thickness of the coating. To evaluate the effect of nozzle geometry in AD, particle trajectory and impact velocity were investigated via computational simulation. A EulerianLagrangian model was used to simulate the gas flow, particle in-flight behavior, as well as particle deposition characteristics on a flat substrate. Three common nozzle geometries in AD were utilized: a converging-diverging nozzle with a slit cross-section (CD-Slit), a converging-barrel nozzle with a slit cross-section (CB-Slit), and a converging-diverging round (CD-Round) nozzle. Moreover, suitable drag coefficient and Nusselt number correlations were used to account for compressibility and rarefaction effects on particle dynamics and heat transfer. The simulation results were compared to the deposition pattern obtained experimentally. The results demonstrate that shape of the nozzle has profound effect on the particle impact velocity and deposition pattern. The CD-Round nozzle provides uniform, thinner coatings ideal for extensive surfaces at a slower deposition rate. In contrast, the CB-Slit nozzle is optimized for maximum coating thickness in narrow, thick linear patterns. The CD-Slit nozzle achieves high deposition rates with uniform coatings and a distinctive cat-ear shaped pattern.