Research Highlights Coating Process Fundamentals CPF
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1 Research Highlights Coating Process Fundamentals CPF
2 Coating Process Fundamentals CPF Investigator Lorraine F. Francis* Expertise Solidification, stress development, microstructure, printing Satish Kumar* Transport processes, interfacial phenomena, microfluidics Marcio S. Carvalho** Fluid mechanics, rheology, numerical methods Alon V. McCormick Curing, thermodynamics & kinetics, NMR, stress development C. Daniel Frisbie Printing processes, printed electronics Chris W. Macosko Rheology, polymer processing Xiang Cheng Colloids, polymers, rheology, visualization Michael Tsapatsis Zeolite and particulate coatings, membranes, separations Wieslaw Suszynski*** Coating process experiments, apparatus, flow visualization *Program Co-Leaders **Pontifica Universidade Catolica, Rio de Janeiro ***Research Engineer and Coating Process and Visualization Laboratory Manager
3 Coating of Rotating Discrete Objects with Complex Surface Geometry Reverse Flows Patterned Cylinders Stents Auto Bodies Contact Lenses Challenge: Non-uniform coating thickness due to surface curvature Model Problem Flow of a liquid film on rotating cylinders r y Imposed Surface Topography & Complex Cross-section Shape 3D Printed Parts g Lens Increasing Rotation Rate Increasing Film Thickness Trapping of liquid may be detrimental to coating quality Slender Cylinders Smooth coatings will likely require simultaneous rotation and drying Film Rupture Liquid Shedding Weihua Li (Kumar)
4 ynamic Wetting Failure and Hydrodynamic Assist in Curtain Coating Stress gradients at IP Capillary-stress gradient Inflection point (IP) DCL Flow rate Q (cm 2 /s) Surfactant promotes wetting failure Surfactant 0.3 wt% SDS in glycerol/water Surfactant-free (glycerol/water) Coating speed U (m/s) Marston et al., Exp. Fluids 46 (2009) 549 Goal: Pressure gradient Wetting failure occurs when capillary forces cannot pump air away Ca crit Understand how surfactants influence wetting failure and hydrodynamic assist in curtain coating Results: Marangoni stresses (surface-tension gradients) promote the onset of wetting failure in curtain coating Marangoni stresses are a possible mechanism for the experimental observations reported by Marston et al. Chen-Yu Liu (Kumar and Carvalho) C.-Y. Liu, E. Vandre, M. S. Carvalho, and S. Kumar, J. Fluid Mech. 808, 290 (2016). U
5 Dynamics of Capillary-Driven Flow in 3D Printed Open Microchannels Objectives Microchannel Fabricate open microchannels with 3D printing Understand flow dynamics in 3D printed microchannels Top view Key Results Open microchannels can be readily printed but are rough and irregular 3D printed surface causes unique contact line motion and flow dynamics Surface roughness lowers capillary filling velocity 3D printing procedure s s s Microchannel Cross section Robert Lade (Francis, Macosko) s Scale bar: 200 μm * Lade et al. Langmuir 2017, 33,
6 Objective Pulsed Irradiation for High-Throughput Curing Applications Investigate curing kinetics of acrylate coatings under intense pulsed light (IPL) Results Limiting conversion depends on the irradiation dose, but not the irradiation dose rate Curing completes within a few milliseconds with a controlled single pulse Ambient-temperature cure and low photoinitiator loading are attained Yuyang Du (Francis, McCormick) *Du, Y.; Williams, B. A. et al. Prog. Org. Coat. 2017
7 Effect of Rheological Properties on Curtain Coating Goal: Study the effect of rheological properties on liquid curtain stability and coating window Method: Rheological characterization, high speed flow visualization and model. High speed visualization of curtain breakup Curtain coating window for Newtonian and viscoelastic liquids Evolution of a perturbation in a Newtonian and viscoelastic liquid sheet Main Result: Effect of rheological properties on the different failure mechanism in curtain coating; Show how liquid formulation may be adjusted to optimize curtain coating process. A. M. Karim, W. Suszynski, L. F. Francis and M. S. Carvalho, AIChEJ, sub., Alireza Karim (Francis and Carvalho) Marisa Bazzi (Carvalho)
8 Slot Coating of Particulate Suspension Goal: Evaluate effect of particle concentration and size on process limits and particle distribution and orientation on the coated film. Main Result: Method: Solve the Navier-Stokes equations for free surface flows coupled with particle concentration and conformation transport equations using the finite element method Accurate prediction of process limits of particle suspension coating. Effect of flow conditions on particle distribution and alignment on coated film. Reboucas, Siqueira, Souza Mendes and Carvalho, JNNFM, vol.234, 2016 I. Siqueira, R. Reboucas and M.S. Carvalho, JNNFM, vol.243, 2017 I. Siqueira, R. Reboucas and M.S. Carvalho, AIChE J, in print, 2017 R. Reboucas and I. Siqueira (Carvalho)
Research Highlights Coating Process Fundamentals CPF
Research Highlights Coating Process Fundamentals CPF Coating Process Fundamentals CPF Investigator Lorraine F. Francis* Expertise Solidification, stress development, microstructure, printing Marcio S.
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