Transparent high-pressure nozzles for visualization of nozzle internal and external flow phenomena

A new design for transparent high-pressure nozzles is presented in this work. This new design enables using the innovative Selective Laser Etching (SLE) method to manufacture transparent nozzles with outstanding accuracy. Therefore, not only the simultaneous visualization of the flow mechanics inside and outside the nozzle is enabled, but the manufacturing method applied also allows for the realization of individual nozzle geometries. Thus, nozzle internal flow phenomena (e.g., cavitation, swirl, and air inlet) and their influence on primary breakup can be analyzed with realistic nozzle geometries, e.g., for automotive applications. In addition, targeted three dimensional nozzle geometric parameters can be designed and manufactured in order to get specific tailor-made spray characteristics (e.g., droplet size distribution, spray angle, and penetration length). The basis for the transparent nozzle design is a two-parted nozzle, consisting of a re-machined original serial nozzle body and a transparent nozzle tip. The innovative SLE is used to produce the geometry of the transparent nozzle tip in fused silica, and laser polishing is utilized to achieve a maximum optical quality of nozzle surfaces for visualization. Bonding of both nozzle parts is achieved by a specially designed adhesive method. For a first feasibility study, a transparent nozzle with a simplified nozzle geometry is manufactured and used for a first study. In this study, simultaneous investigation of nozzle internal flow phenomena and their impact on spray breakup are visualized. First microscopic images of the nozzle internal flow show the formation of cavitation, its effect on nozzle internal temperature (apparent by differences in the fluid refractive index), and also the corresponding impact on spray breakup during injection. The penetration of ambient gas into the nozzle is verified at the end of injection as well as the influence of this air on the spray formation during the start of injection.