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

The archetypal feature of a viscoplastic fluid is its yield stress: If the material is not sufficiently stressed, it behaves like a solid, but once the yield stress is exceeded, the material flows like a fluid. Such behavior characterizes materials common in industries such as petroleum and chemical processing, cosmetics, and food processing and in geophysical fluid dynamics. The most common idealization of a viscoplastic fluid is the Bingham model, which has been widely used to rationalize experimental data, even though it is a crude oversimplification of true rheological behavior. The popularity of the model is in its apparent simplicity. Despite this, the sudden transition between solid-like behavior and flow introduces significant complications into the dynamics, which, as a result, has resisted much analysis. Over recent decades, theoretical developments, both analytical and computational, have provided a better understanding of the effect of the yield stress. Simultaneously, greater insight into the material behavior of real fluids has been afforded by advances in rheometry. These developments have primed us for a better understanding of the various applications in the natural and engineering sciences.

Yielding to Stress: Recent Developments in Viscoplastic Fluid Mechanics

Precise, tunable emulsions and foams produced in microfluidic geometries have found wide application in biochemical analysis and materials synthesis and characterization. Superb control of the volume, uniformity, and generation rate of droplets and bubbles arises from unique features of the microscale behavior of fluid interfaces. Fluid interfaces confined within microfluidic channels behave quite differently than their counterparts in unbounded flows. Confinement inhibits capillary instabilities so that breakup occurs by largely quasi-static mechanisms. The three-dimensional flow near confined interfaces in rectangular geometries and feedback effects from resistance changes in the entire microfluidic network play important roles in regulating the interfacial deformation. Timescales for transport of surfactants and particles to interfaces compete with flow timescales at the microscale, providing further opportunity for tuning the interfacial coverage and properties of individual droplets and bubbles.

Droplets and Bubbles in Microfluidic Devices

Yield stress fluids are encountered in a wide range of applications: toothpastes, cements, mortars, foams, muds, mayonnaise, etc. The fundamental character of these fluids is that they are able to flow (i.e., deform indefinitely) only if they are submitted to a stress above some critical value. Otherwise they deform in a finite way like solids. The flow characteristics of such materials are difficult to predict as they involve permanent or transient solid and liquid regions that are generally hard to locate a priori. Here we review the present state of the art as it appears from experimental data for flows of simple (non-thixotropic) yield stress fluids under various conditions, viz., uniform flows in straight channels or rheometrical geometries, complex stationary flows in channels of varying cross-section such as extrusion, expansion, flow through a porous medium, transient flows such as flows around obstacles, spreading, spin-coating, squeeze flow, and elongation. The effects of surface tension, confinement, and secondary flows are also reviewed. We focus especially on experimental work identifying internal flow characteristics that can be compared with numerical predictions. It is shown in particular that: (i) deformations in the solid regime can play a critical role in transient flows; (ii) the yield character is not apparent in the flow field when the boundary conditions impose large deformations; (iii) the yield character is lost in secondary flows.

Yield stress fluid flows: A review of experimental data

The effects of plastic mulch on plant microclimate are reviewed with specific focus on the transfer of energy within the crop microclimate. An energy transfer accounting system (surface energy balance) is reviewed and data representing the energy balance of a mulched field are presented.

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Microclimate modification with plastic mulch.

We study the evaporation rate from single drops as well as collections of drops on a solid substrate, both experimentally and theoretically. For a single isolated drop of water, in general the evaporative flux is limited by diffusion of water through the air, leading to an evaporation rate that is proportional to the linear dimension of the drop. Here, we test the limitations of this scaling law for several small drops and for very large drops. We find that both for simple arrangements of drops, as well as for complex drop size distributions found in sprays, cooperative effects between drops are significant. For large drops, we find that the onset of convection introduces a length scale of approximately 20 mm in radius, below which linear scaling is found. Above this length scale, the evaporation rate is proportional to the surface area.

Evaporation of water

We study the impact and subsequent retraction of aqueous surfactant-laden drops upon high-speed impact on hydrophobic surfaces. Without surfactants, a rapid expansion of the drop due to the fluid inertia is followed by a rapid retraction, due to the wetting incompatibility. With surfactants, the retraction can be partly or completely inhibited. We provide quantitative measurements showing that both the expansion and the retraction dynamics depend not only on the equilibrium surface tension (ST) but also on the dynamic tension of the surfactant solutions; the latter varies significantly between different surfactants.

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Impact dynamics of surfactant laden drops: dynamic surface tension effects

It is shown experimentally that surfactants can change the thinning rate of fluid necks undergoing rupture. In the case of two-fluid pinch-off, two or three linear regimes are observed for the variation of the neck radius versus time. The surface tension in the neck region changes with time, as a result of surfactant depletion. Similar results are obtained for the case of a single fluid pinching in air. The depletion of surfactant can be either partial or complete depending on the rate of transport of the surfactant from the bulk to the surface.

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Effect of surface tension variations on the pinch-off behavior of small fluid drops in the presence of surfactants.

We study the pinch-off dynamics of droplets of yield stress and shear thinning fluids. To separate the two non-Newtonian effects, we use a yield stress material for which the yield stress can be tuned without changing the shear thinning behavior, and a shear thinning system (without a yield stress) for which the shear thinning can be controlled over a large range, without introducing too much elasticity into the system. We find that the pinch-off remains very similar to that of constant viscosity Newtonian liquids, and consequently thinning in shear flow does not imply a thinning in elongational flow.

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Drop formation in non-Newtonian fluids.

By examining the rupture of fluid necks during droplet formation of surfactant-laden liquids, we observe deviations from expected behaviour for the pinch-off of such necks. We suggest that these deviations are due to the presence of a dynamic (time-varying) interfacial tension at the minimum neck location and extract this quantity from our measurements on a variety of systems. The presence of such dynamic interfacial tension effects should change the rupture process drastically. However, our measurements show that a simple ansatz, which incorporates the temporal change of the interfacial tension, allows us to understand the dynamics of thinning. This shows that this dynamics is largely independent of the exact details of what happens far from the breakup location, pointing to the local nature of the thinning dynamics.

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Mounir Aytouna

Papers

Evaporation of water

Impact dynamics of surfactant laden drops: dynamic surface tension effects

Effect of surface tension variations on the pinch-off behavior of small fluid drops in the presence of surfactants.

Drop formation in non-Newtonian fluids.

Dynamic interfacial tension effects in the rupture of liquid necks