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. 2020 Jul 20;28(15):21749-21765.
doi: 10.1364/OE.390131.

3D printing of gas-dynamic virtual nozzles and optical characterization of high-speed microjets

Reza Nazari, Sahba Zaare, Roberto C Alvarez, Konstantinos Karpos, Trent Engelman, Caleb Madsen, Garrett Nelson, John C H Spence, Uwe Weierstall, Ronald J Adrian, Richard A Kirian

3D printing of gas-dynamic virtual nozzles and optical characterization of high-speed microjets

Reza Nazari et al. Opt Express. .

Abstract

Gas dynamic virtual nozzles (GDVNs) produce microscopic flow-focused liquid jets and droplets and play an important role at X-ray free-electron laser (XFEL) facilities where they are used to steer a stream of hydrated biomolecules into an X-ray focus during diffraction measurements. Highly stable and reproducible microjet and microdroplets are desired, as are flexible fabrication methods that enable integrated mixing microfluidics, droplet triggering mechanisms, laser illumination, and other customized features. In this study, we develop the use of high-resolution 3D nano-printing for the production of monolithic, asymmetric GDVN designs that are difficult to fabricate by other means. We also develop a dual-pulsed nanosecond image acquisition and analysis platform for the characterization of GDVN performance, including jet speed, length, diameter, and directionality, among others. We show that printed GDVNs can form microjets with very high degree of reproducibility, down to sub-micron diameters, and with water jet speeds beyond 170 m/s.

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Conflict of interest statement

The authors declare no conflicts of interest.

Figures

Fig. 1.
Fig. 1.
A picture of an operating GDVN.
Fig. 2.
Fig. 2.
Design dimensions of the Design 1 in micrometers.
Fig. 3.
Fig. 3.
Drawing of the nozzle Design 2 (dimensions are in micrometers).
Fig. 4.
Fig. 4.
An assembled 3D printed nozzle
Fig. 5.
Fig. 5.
SEM images of a nozzle from Design 2. Only half of the nozzle was printed in order to reveal the internal structure.
Fig. 6.
Fig. 6.
Schematic of the test station. Helium gas drives the liquid jet and the pressure and mass flow rate are monitored upstream of the glass capillary that leads to the nozzle. An HPLC pump drives the liquid (water) and a flowmeter measures its volumetric flow rate. Nitrogen gas and isopropanol are used to clean and dry nozzles, particularly when running samples other than water. The nozzle is located in a small chamber at ∼1 mbar pressure. A pulsed ∼100 ns laser provides brightfield illumination for the high-frame-rate camera, and electronic delay system allows for doublets of images.
Fig. 7.
Fig. 7.
Illustration of image processing steps. (a) Raw image before processing steps. (b) Binary image after background subtraction and thresholding. (c) Perimeter of extracted jet region. (d) Pair of extracted droplet series separated in time by 550 ns. The droplet colors indicate matching droplets in the image pair.
Fig. 8.
Fig. 8.
He pressure at the inlet of the gas capillary versus He flow rate for a nozzle of Design 1, showing that the liquid flow does not effect the gas flow in the measurements.
Fig. 9.
Fig. 9.
(a) Plots of Jet velocity versus helium flow rate for different liquid (water) flow rates for 5 different nozzles from Design 1 and (b) 5 different nozzles from Design 2. (c) Plots of Jet length versus helium flow rate for different liquid (water) flow rates for 5 different nozzles from Design 1 and (d) 5 different nozzles from Design 2. Symbol colors distinguish liquid flow rates, while symbol shapes distinguish different nozzles.
Fig. 10.
Fig. 10.
(a) Jet diameter versus helium flow rate for different liquid (water) flow rates for 5 different nozzles from Design 1 and (b) 5 different nozzles from Design 2. (c) Jet angle versus helium flow rate for different liquid (water) flow rates for 5 different nozzles from Design 1 and (d) 5 different nozzles from Design 2. Symbol colors distinguish liquid flow rates, while symbol shapes distinguish different nozzles.
Fig. 11.
Fig. 11.
(a) Jet diameter versus helium flow rate for different liquid (water) flow rates for a nozzle from Design 2. (b) Median droplet diameter versus helium flow rate for different liquid (water) flow rates for a nozzle from Design 2. (c) Median droplet diameter versus calculated jet diameter for a nozzle from Design 2. (d) Plot of Estimated pressure inside the nozzle versus liquid jet Reynolds number for 5 nozzles from Design 1 under different operating conditions.
Fig. 12.
Fig. 12.
(a) Plot of liquid jet Weber number versus liquid jet Reynolds number for 5 nozzles from Design 1 under different operating conditions. (b) Plot of liquid jet Reynolds number versus He flow rate for 5 nozzles from Design 1 under different operating conditions, (c) Plot of liquid jet Weber number versus He flow rate for 5 nozzles from Design 1. (d) Plot of calculated sheath gas Reynolds number versus helium flow rate for 5 nozzles from Design 1 under different operating conditions. Symbol colors distinguish liquid flow rates, while symbol shapes distinguish different nozzles.
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