A Computational Fluid Dynamics (CFD) Study of Material Transport and Deposition in Aerosol Jet Printing (AJP) Process

The objective of this work is to forward a 3D computational fluid dynamics (CFD) model to explain the aerodynamics behind aerosol transport and deposition in aerosol jet printing (AJP). The CFD model allows for: (i) mapping of velocity fields as well as particle trajectories; and (ii) investigation of post-deposition phenomena of sticking, rebounding, spreading, and splashing. The complex geometry of the deposition head was modeled in the ANSYS-Fluent environment, based on a patented design as well as accurate measurements, obtained from 3D X-ray CT imaging. The entire volume of the geometry was subsequently meshed, using a mixture of smooth and soft quadrilateral elements, with consideration of layers of inflation to obtain an accurate solution near the walls. A combined approach — based on the density-based and pressure-based Navier-Stokes formation — was adopted to obtain steady-state solutions and to bring the conservation imbalances below a specified linearization tolerance (10⁻⁶). Turbulence was modeled, using the realizable k-ε viscose model with scalable wall functions. A coupled two-phase flow model was set up to track a large number of injected particles. The boundary conditions were defined based on experimental sensor data. A single-factor factorial experiment was conducted to investigate the influence of sheath gas flow rate (ShGFR) on line morphology, and also validate the CFD model.