Additive manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire or sheets in a process that proceeds layer by layer. Many techniques (using many different names) have been developed to accomplish this via melting or solid-state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid-state precipitation, mechanical properties and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Only a few alloys have been developed for commercial production, but recent efforts are presented as a path for the ongoing development of new materials for AM processes.

The metallurgy and processing science of metal additive manufacturing

Precise and effective control of droplet generation is critical for applications of droplet microfluidics ranging from materials synthesis to lab-on-a-chip systems. Methods for droplet generation can be either passive or active, where the former generates droplets without external actuation, and the latter makes use of additional energy input in promoting interfacial instabilities for droplet generation. A unified physical understanding of both passive and active droplet generation is beneficial for effectively developing new techniques meeting various demands arising from applications. Our review of passive approaches focuses on the characteristics and mechanisms of breakup modes of droplet generation occurring in microfluidic cross-flow, co-flow, flow-focusing, and step emulsification configurations. The review of active approaches covers the state-of-the-art techniques employing either external forces from electrical, magnetic and centrifugal fields or methods of modifying intrinsic properties of flows or fluids such as velocity, viscosity, interfacial tension, channel wettability, and fluid density, with a focus on their implementations and actuation mechanisms. Also included in this review is the contrast among different approaches of either passive or active nature.

Passive and active droplet generation with microfluidics: a review

Pendant drop tensiometry offers a simple and elegant solution to determining surface and interfacial tension - a central parameter in many colloidal systems including emulsions, foams and wetting phenomena. The technique involves the acquisition of a silhouette of an axisymmetric fluid droplet, and iterative fitting of the Young-Laplace equation that balances gravitational deformation of the drop with the restorative interfacial tension. Since the advent of high-quality digital cameras and desktop computers, this process has been automated with high speed and precision. However, despite its beguiling simplicity, there are complications and limitations that accompany pendant drop tensiometry connected with both Bond number (the balance between interfacial tension and gravitational forces) and drop volume. Here, we discuss the process involved with going from a captured experimental image to a fitted interfacial tension value, highlighting pertinent features and limitations along the way. We introduce a new parameter, the Worthington number, Wo, to characterise the measurement precision. A fully functional, open-source acquisition and fitting software is provided to enable the reader to test and develop the technique further.

Measurement of surface and interfacial tension using pendant drop tensiometry

Review on the physics of electrospray: From electrokinetics to the operating conditions of single and coaxial Taylor cone-jets, and AC electrospray

Miniaturization has been the driving force of scientific and technological advances over recent decades. Recently, flexibility has gained significant interest, particularly in miniaturization approaches for biomedical devices, wearable sensing technologies, and drug delivery. Flexible microfluidics is an emerging area that impacts upon a range of research areas including chemistry, electronics, biology, and medicine. Various materials with flexibility and stretchability have been used in flexible microfluidics. Flexible microchannels allow for strong fluid-structure interactions. Thus, they behave in a different way from rigid microchannels with fluid passing through them. This unique behaviour introduces new characteristics that can be deployed in microfluidic applications and functions such as valving, pumping, mixing, and separation. To date, a specialised review of flexible microfluidics that considers both the fundamentals and applications is missing in the literature. This review aims to provide a comprehensive summary including: (i) Materials used for fabrication of flexible microfluidics, (ii) basics and roles of flexibility on microfluidic functions, (iii) applications of flexible microfluidics in wearable electronics and biology, and (iv) future perspectives of flexible microfluidics. The review provides researchers and engineers with an extensive and updated understanding of the principles and applications of flexible microfluidics.

Flexible Microfluidics: Fundamentals, Recent Developments, and Applications.

We present a robust and computationally efficient numerical scheme for simulating steady electrohydrodynamic
atomization processes (electrospray). The main simplification assumed in this
scheme is that all the free electrical charges are distributed over the interface. Comparison of the
results with those calculated with a Volume-of-Fluid method showed that the numerical scheme
presented here accurately describes the flow pattern within the entire liquid domain. Experiments
were performed to partially validate the numerical predictions. The simulations reproduced accurately
the experimental shape of the liquid cone-jet, providing correct values of the emitted electric
current even for configurations very close to the cone-jet stability limit.

/pdf/numerical-simulation-of-electrospray-in-the-cone-jet-mode-10032bcyqp.pdf

Numerical simulation of electrospray in the cone-jet mode.

In the flow focusing technique, a liquid flow rate Q is injected through a microcapillary to form a meniscus attached to its edge. The meniscus is stretched until a thin jet tapers from its tip due to the action of a gas stream driven by a pressure drop Δp. Both the liquid jet and the gas stream cross the orifice of a plate located in front of the capillary at a distance H. In the present work, the stability of both the tapering liquid meniscus and the emitted jet is analyzed experimentally. Three regimes are identified: (i) the steady jetting regime, where the liquid meniscus is stable and the jet is convectively unstable; (ii) the local instability regime, where the liquid meniscus is stable and the jet is absolutely unstable; and (iii) the global instability regime, where the liquid meniscus is unstable. The mechanisms responsible for the transitions between those regimes are described. The experiments show the existence of a minimum value Qmin of the flow rate Q below which flow focusing is globally u...

Global and local instability of flow focusing: The influence of the geometry

We examine both theoretically and experimentally the breakup of a pendant drop loaded with an insoluble surfactant. The experiments show that a significant amount of surfactant is trapped in the resulting satellite droplet. This result contradicts previous theoretical predictions, where the effects of surface tension variation were limited to solutocapillarity and Marangoni stresses. We solve numerically the hydrodynamic equations, including not only those effects but also those of surface shear and dilatational viscosities. We show that surface viscosities play a critical role to explain the accumulation of surfactant in the satellite droplet.

/pdf/influence-of-the-surface-viscosity-on-the-breakup-of-a-4wno6winzx.pdf

Influence of the surface viscosity on the breakup of a surfactant-laden drop

The characterization of the extensional rheology of polymeric solutions is important in several applications and industrial processes. Filament stretching and capillary breakup rheometers have been developed to characterize the extensional properties of polymeric solutions, mostly for high-viscosity fluids. However, for low concentration polymer solutions, the measurements are difficult using available devices, in terms of the minimum viscosity and relaxation times that can be measured accurately. In addition, when the slow retraction method is used, solvent evaporation can affect the measurements for volatile solvents. In this work, a new setup was tested for filament breakup experiments using the slow retraction method, high-speed imaging techniques, and an immiscible oil bath to reduce solvent evaporation and facilitate particle tracking in the thinning filament. Extensional relaxation times above around 100 μs were measured with the device for dilute and semi-dilute polymer solutions. Particle tracking velocimetry was also used to measure the velocity in the filament and the corresponding elongation rate, and to compare with the values obtained from the measured exponential decay of the filament diameter.

/pdf/measurement-of-relaxation-times-in-extensional-flow-of-51dxahoxlp.pdf

Measurement of relaxation times in extensional flow of weakly viscoelastic polymer solutions

Polydimethylsiloxane (PDMS), due to its remarkable properties, is one of the most widely used polymers in many industrial and medical applications. In this work, a technique based on a flow focusing technique is used to produce PDMS spherical particles with sizes of a few microns. PDMS precursor is injected through a hypodermic needle to form a film/reservoir over the needle's outer surface. This film flows towards the needle tip until a liquid ligament is steadily ejected thanks to the action of a coflowing viscous liquid stream. The outcome is a capillary jet which breaks up into PDMS precursor droplets due to the growth of capillary waves producing a micrometer emulsion. The PDMS liquid droplets in the solution are thermally cured into solid microparticles. The size distribution of the particles is analyzed before and after curing, showing an acceptable degree of monodispersity. The PDMS liquid droplets suffer shrinkage while curing. These microparticles can be used in very varied technological fields, such as biomedicine, biotechnology, pharmacy, and industrial engineering.

/pdf/generation-of-micro-sized-pdms-particles-by-a-flow-focusing-496pgg6jyw.pdf

E. J. Vega

Papers

Numerical simulation of electrospray in the cone-jet mode.

Global and local instability of flow focusing: The influence of the geometry

Influence of the surface viscosity on the breakup of a surfactant-laden drop

Measurement of relaxation times in extensional flow of weakly viscoelastic polymer solutions

Generation of micro-sized PDMS particles by a flow focusing technique for biomicrofluidics applications