Simulation of the spreading of a gas-propelled micro-droplet upon impact on a dry surface using a lattice-Boltzmann approach

Spray cooling is one of the most promising methods of cooling high heat flux electronics. Depending on the type of the nozzle, spray cooling can be categorized as single-phase or two-phase. In the latter, which is known to be more effective, a secondary gas is used to further pressurize the liquid and form smaller droplets at higher velocities. The gas is also assumed to assist the spreading phase by imposing normal and tangential forces on the droplet free surface which adds to the complicated hydrodynamics of the droplet impact. Moreover, the order of magnitude of droplet size in spray cooling is 10−6 m, thereby introducing a low Weber and Reynolds numbers’ impact regime which heretofore has not been well understood. A 3D lattice Boltzmann method was implemented to simulate the impact of a single micro-droplet on a dry surface both in ambient air and under a stagnation gas flow. Two cases were closely compared and correlations were proposed for the instantaneous spreading diameter. Contrary to recent findings at higher impact Weber and Reynolds numbers, it was found that a stagnation flow only significantly affects the spreading phase for Ca* ≥ 0.35 but has little influence on the receding physics.