MEASUREMENT OF SPRAY COOLING HEAT TRANSFER

USING AN INFRARED-TECHNIQUE IN COMBINATION WITH

THE PHASE-DOPPLER TECHNIQUE AND A PATTERNATOR

F. Puschmann*, E. Specht*, J. Schmidt*

*Otto-von-Guericke-University Magdeburg, Institute of Fluid Dynamics and Thermodynamics,

Universitätsplatz 2, D-39106 Magdeburg

ABSTRACT
A measurement setup-up to determine heat transfer and spray characteristics is presented. Spray properties are measured with a
2D-Phase-Doppler-Anemometer and a patternator, heat transfer is measured based on determining the surface temperature by
means of infrared thermal imaging. The combination of these two measurement techniques makes it possible to determine heat
transfer with high resolution in time and space and also to specify the influence of spray properties on the received heat
transfer. Results from investigations in water spray quenching and evaporation quenching are presented to clarify the
measurement procedure.

1. INTRODUCTION heated surface completely evaporate and do not merge in a

water film, as is the case in water spray cooling. In this
In many heat treatment processes, metallic products must quenching process the Leidenfrost problem does not arise
be quenched in a specified way. The aim of these quenching and high quenching speeds can nevertheless be achieved.
processes is to regulate material properties such as strength, Investigations on this topic can benefit from results on
hardness, machinability and so forth. At the same time, the investigations into the impact of single drops on hot surfaces
quenching process must carried out with defined precision, [9-12].
as only then the necessary quality can be achieved. In
addition, using defined quenching, warping of a work piece
can be reduced. During tempering, for example, steels are PDA-Analysis unit PDA-
Receiver Metal sheet
quenched quickly and defined from approx. 900°C to 400°C PDA- 0.1 - 0.3 mm Registration
Data
in order to achieve a certain degree of hardness. of operation
IR Analysis Nozzle conditions
To achieve high quenching speeds, liquid is used for unit 150 l/h
cooling. As an example for a cooling process with water as 5bar;22°C

IR- IR Radiation
liquid there is water spray quenching, used for example in picture
Transmitter
continuous casting. Here, however, the so-called Leidenfrost
problem arises. Above the Leidenfrost point a steam film
Pump
forms between the hot surface and the cooling liquid. The
steam film hinders direct contact between the surface and IR Camera 300 A
0.2 mm/Pixel
cooling liquid and as a result greatly reduces the heat Direct current Water
transfer. If the process falls below the Leidenfrost source
Laser (4 Watt)
temperature, the isolating steam film breaks down. The hot
surface is in direct contact with the cooling liquid which
leads to intense cooling and consequently leads to a greatly Figure 1. Experimental set-up
increased quenching speed. Besides the cooling conditions
such as properties and flow of the liquid, the Leidenfrost
temperature is also dependent on the body geometry, the The measurement set-up sketched in Fig. 1 was designed
surface roughness and the parameters of the material to be to investigate both quenching methods. With this set-up the
cooled. parameters of the spray are determined using a 2D-Phase-
Another quenching process using liquid is evaporation Doppler-Anemometer. At the same time, heat transfer is
quenching with atomised sprays. Finely atomised water is measured with a measurement technique based on an infrared
sprayed on the surface to be cooled. The quantity of water camera. The aim of measurements with this set-up is to find
must be limited to an extent that the individual drops on the out the influence of the main parameters such as
- impingement density, about 6.4 m/s. It should be noted that the aperture angle of
- drop diameter, the flat-jet nozzle was 105° and, hence, the overall length of
- drop velocity and the spray jet in the measuring plane was about 520 mm. The
- surface temperature figure shows a section of the centre exhibiting a width of 200
on heat transfer. In the case of producing the water spray mm.
with the help of compressed air, the impact of the air flow is
another influencing parameter to be investigated.
150 7

Mean volumetric drop diameter [µm]

140
2. EXPERIMENTAL SET-UP 6,5

Mean drop velocity [m/s]

130 v
6
The measuring set-up sketched in Fig. 1 was designed to
120
investigate drop size and velocity at the same time as heat D30 5,5
transfer. Thereby the spray characteristic is measured with a 110
2D-Phase-Doppler-Anemometer (PDA), the heat transfer is 5
100 Nozzle: D25381-13-105/20-1
measured on the basis of determining the surface temperature Measuring planes: 200 mm
by means of infrared thermal imaging. Impingement density 90
Nozzle pressure: 5bar 4,5
Flow rate: 318kg/h
is measured not only by PDA, but also by a patternator.
80 4
-100 -50 0 50 100
2.1 Drop Diameter and Velocity Measuring position [mm]

The distribution of drop sizes and drop velocities of the

Figure 3. Drop Size and Velocity
water spray is measured by means of a PDA. The principle of
this laser-based measurement system is sketched in Fig. 2. It
is an optical measuring system which is able to perform non-
contact and simultaneous measurements of the velocity and 2.2 Impingement Density
the diameter of spherical particles. The sensing volume of the
A patternator as depicted in Fig. 4 was used to measure
PDA is fairly small, ensuring high resolution in terms of time
the water impingement density. The water drops of a spray
and area. It is able to identify individual drops passing
were collected by means of collecting tubes which were
through the sensing volume. Due to its high laser power of 4
arranged in the spray jet and exhibited a diameter of DR=10
Watt it is an excellent device for performing measurements
in misty and steamy environments. mm, over a period ∆t. The amount of water MW collected can
be used in the equation

Air Water 4⋅Mw

m& S = (1)
∆t ⋅ π ⋅ D R2
Nozzle
Probe volume
to compute the water impingement density. The water
impingement density can be also measured by means of the
Laser (max. 4 W)
PDA, but due to the high error rate it is necessary to employ
another measuring system, i.e. a patternator as in this case
[1].
Transmitter 30 ° (off-axis angle)

Receiver Water spray

Analysis unit

Figure 2. Principle of the PDA system Patternator

Fig. 3 depicts the distribution of drop size and drop

velocity for a flat-spray nozzle as used in continuous casting.
The mean volumetric diameter is presented as a function of
the measuring position. The measuring plane was located at a
distance of 200 mm in front of the nozzle. The measuring Collective
containment
position was the distance measured across the length of the
flat jet from its centreline. A pressure of 5 bar was applied to
the nozzle resulting in a water flow rate of 318 kg/h. The
mean volumetric diameter was about 110 µm in the centre of Figure 4. Patternator system
the spray jet. The drop size increased towards the border.
Reducing towards the border, the mean drop velocity was
 Fig. 5a shows the distribution of water impingement the heat away from the hot metal sheet surface. In a
density obtained with the flat-spray nozzle as a function of stationary measuring process the metal sheet temperature
the measuring position. As can be seen, the mean assumed to be a value of a function of the local heat transfer
impingement density amounting to 4.5 kg/m2s is fairly coefficient. The higher this coefficient, the lower was the
constant under the operating conditions described above, local metal sheet temperature. In a non-stationary measuring
forming individual skeins at the nozzle. The results of two process the metal sheet was heated to an initial temperature
measurements are shown to document the reproducibility of without being cooled by water spray. Subsequently, the spray
the measuring results obtained with this measuring jet was released cooling down the sheet. Due to the small
procedure. thickness of the metal sheet between 0.1 mm and 0.3 mm,
both measuring procedures yielded an almost identical
temperature distribution on the side sprayed on and the side
5,5
not sprayed on. The local distribution, and time distribution
in the non-stationary case, of the surface temperature of the
Water impingement density [kg/m²/s]

5,3
non-impinged side were recorded by means of an infrared
5,1
camera. On the relevant side, the sheet exhibited a specific
4,9
coating with an emission capability that had been determined
4,7
before as a function of temperature. A local temperature
4,5
resolution of up to 0.2 mm/pixel can be achieved by using a
4,3
telephoto lens with a supplementary lens. The local
4,1 Nozzle: D25381-13-105/20-1 distribution of the heat transfer coefficient can be calculated
3,9 Measuring planes: 200 mm
Nozzle pressure: 5bar from the temperature distribution. The difference between
3,7 Flow rate: 318kg/h the surface temperature distribution measured on the rear
3,5
-50 -30 -10 10 30 50
side and the required surface temperature distribution can be
Measuring position [mm]
determined using a numerical solution of the problem of
thermal conduction. Thereby the multidimensional
conduction of heat within the sheet was taken into account.
Figure 5a. Impingement Density flat-spray nozzle
Stationary measuring procedure. In the case of stationary
measuring of surface temperature distribution a constant
Fig. 5b shows the distribution of water impingement value under cooling conditions was assumed and which was
density obtained with an internall-mixing air-assist atomizer recorded by means of an infrared camera. This surface
as a function of patternator tube. The air pressure at the temperature distribution can be used to compute the
nozzle serves as parameter. As can be seen, the impingement distribution of the heat transfer coefficient. The heat flux
density are greatest in the centre of the spray, decreasing to resulting from the current flow through the metal sheet and,
its border. The impingement density decreases with hence, from the source of heat applied, is calculated by
increasing air pressure. means of the electric power Pel supplied and the area A of the
metal sheet as follows

I 2 ⋅ R  ρ el  2
q& H (ϑ H ) = (ϑ H )⋅ I 2 ,
Pel
3 Air pressure: = =  (2)
A b⋅l  s  b
Water impingement density

2,5 2 bar
3 bar
2 where ϑH is the corrected metal sheet temperature, I the
[kg/m²/s]

4 bar electric current passed through the metal sheet, R the

1,5
1 temperature-dependent specific resistance of the metal with
0,5
0 established in special measurements as a function of
1 2
Figure 5b. Impingement Density
2.3 Heat Transfer
The measuring procedure to determine the heat transfer
within a fairly short period of time and with locally high
resolution is presented in Fig. 1 [2,3,4]. It is based on
determining the surface temperature by means of infrared
thermal imaging. To determine heat transfer, a thin metal
sheet was arranged in front of the spray-generating nozzles
and supplied with a constant electric current. The water leads
electrical resistance of the metal sheet, (ρel/s) the
Water flow rate: 6 kg/h reference to the sheet thickness s, and b the width of the
Distance: 200 mm sheet. The specific resistance of the metal sheet was
3 4 5 6 7 8 9 10 temperature. Since the specific resistance of the used metal is
Tube # slight temperature dependent, it is assumed that the specific
resistance is constant at an investigated temperature level. If
the temperature difference over the metal sheet area is wide,
heat conduction in the metal sheet plane must be taken into
account.
During the measurement the sheet was not only cooled by
the spray jet. Radiation of energy and a convective heat
transfer must also be considered under the conditions of high
temperatures. This heat transfer is included as the heat loss.
The model to calculate the heat loss is verified by
measurements where the metal sheet is heated up and only
cooled by the heat loss. The heat flux q& Sp (ϑH) led away by
the spray jet is calculated by
 q& Sp (ϑ H ) = q& H (ϑ H ) − q&V (ϑ H ),
where q&V (ϑH) is the temperature-dependent heat loss.
Hence, the obtained heat transfer coefficient αSp can be
calculated by using the corrected surface temperature ϑH and
the spray jet temperature ϑSp using the following equation
(3) to the entire sprayed surface, if the properties of the atomised
stream only depend on the radial position in the spray cone
and on the distance from the nozzle. As an example the heat
transfer coefficient is determined by using the non-stationary
measuring procedure.

q& Sp (ϑ H (x, y )) 600,0°C

α Sp (x, y ) =
600
600 °C
(ϑ H (x, y )− ϑSp ) . (4)

Non-stationary measuring procedure. Under the 400

conditions of high heat transfer coefficients and high surface x [mm]
temperatures it is difficult to obtain and keep a stationary
operating point and in some cases this is even impossible due
to the limits of the electric power available. Hence, heat 200
200 °C
200,0°C
transfer coefficients were determined by means of non-
stationary techniques under the conditions of high heat flux.
To this end, the metal sheet was heated to an initial
temperature supplying a constant current and, subsequently, Figure 6. Thermographic picture of an IR Sequence
cooled down using a spray jet. The time-dependent
distribution of temperature on the metal sheet surface was
3.2 Run of temperature
measured.
For calculating the total heat transfer coefficients α For calculating the heat transfer coefficient from the non-
neglecting conduction, the differential equation stationary measuring procedure the test metal sheet is heated
up to an initial temperature and then abruptly cooled down
dϑ H
ρ M ⋅ V ⋅ cM ⋅
dt
(
− Pel = α ⋅ A ⋅ ϑ Sp − ϑ H ) (5) by the water spray. This process is recorded in a sequence of
pictures by the IR camera. From three sequences the run of
temperature with time during the cooling down process is
can be established using an energy balance at the metal sheet. plotted in Fig. 7 for the three different water flows 5.7 kg/h,
Here, ρM is the density of the metal sheet, V its volume, and 9.9 kg/h and 13.1 kg/h. In Fig. 7 every plotted point of one
cM its specific thermal capacity. Dividing by the area of the curve is a measured temperature value from one picture of a
metal sheet and converting the ratio Pel/A as described in Eq. taken sequence. The measured point on the metal sheet
(2), we obtain surface is in the centre of the spray, 24 mm on the x-
coordinate of Fig. 6. The air flow used for atomisation
dϑ H I 2 ρ remains constant for all three experiments. It can be seen that
ρ M ⋅ s ⋅ cM ⋅ − 2 ⋅  el

( )
 = α ⋅ ϑ Sp − ϑ H . (6) the higher the water flow is, the faster the metal sheet is
dt b  s  cooled down and the steeper the gradient of the temperature
curves is. For very faster cooling down processes the IR
With the well known time-dependent surface temperature camera resolution in time is not sufficient. In this case
it is possible to compute the total heat transfer coefficient. sequences have to be taken in line-scan mode with a
This coefficient is corrected by heat losses. The IR camera resolution in time of 2500 Hz.
operates in line-scan mode with a data rate of 2500 Hz. In
this case a high resolution in time of surface temperature is
obtained.
800
Surface temperature [°C]

Water flow:
3. RESULTS ON NON-STATIONARY MEASURING 700
PROCEDURE
600
In the following the evaluation of the non-stationary
measuring procedure is demonstrated. 500
5.7 kg/h
400
3.1 IR Sequence 13.1 kg/h 9.9 kg/h
300
Fig. 6 shows a thermographic picture of an IR Sequence, 0 1 2 3 4
in which the temperature distribution of the metal sheet is Time [s]
recognizable. In this test the metal sheet was cooled with a
water spray, which was sprayed perpendicularly onto the
surface of the test metal sheet. The spray was produced using Figure 7. Run of temperature
an internal-mixing air-assisted atomizer. The cooling effect
decreases radially. The results then obtained can be applied
3.3 Heat flux
From the time-dependent surface temperature plotted in
Fig. 7 the heat flux is calculated using Eq. (6). Thereby, the
heat flux is equal to the right side of Eq. (6), whereas the heat
losses are taken into account. In Fig. 8 the surface
temperature dependent heat flux is plotted for the three water
flows from Fig. 7. It can be seen that for a constant surface
temperature the higher the water flow is, the higher the heat
flux is. For a constant water flow the heat flux increases with
increasing surface temperature. In the investigated area the
gradient of the increase of heat flux with increasing surface
temperature is nearly independent of the water flow.
800
Water flow:
700
13.1 kg/h
600
Heat flux [kW/m²]
coefficient on surface temperature increases with increasing
water flow.
The results are taken from experiments on evaporation
quenching, that means although surface temperature is above
Leidenfrost temperature, there is no water film on the hot
surface.
4. RESULTS ON STATIONARY MEASURING
PROCEDURE
In past investigations the heat transfer in water spray
quenching was investigated [4,7,8]. The results of these
investigation are shown in Fig. 10 in comparison to other
researchers (Fujimoto [5] and Müller/Jeschar [6]). Our own
investigations were carried out with the stationary measuring
procedure at a surface temperature of 550° C, a drop velocity
of 8 m/s and a mean volumetric drop diameter of 60 µm. It
can be seen that the water impingement density exerts a

500 major influence on the heat transfer coefficients achieved.

9.9 kg/h When the water impingement density increases, the obtained
400
heat transfer coefficient also increases. Our own
300
examinations result in higher heat transfer coefficients for
200 constant impingement density, but the same gradient of heat
5.7 kg/h
100 transfer coefficient with increasing impingement density as
0 Fujimoto. The curve of Müller/Jeschar has a lower gradient.
300 400 500 600 700 800 In order to compare the results of other researchers with our
Surface temperature [°C] own results it has to be taken into account that the
measurement set-up of other researchers measure the heat
transfer over a more or less large area. In most publications
Figure 8. Heat flux
only the impingement density is investigated as an
influencing parameter. But as mentioned before [4], also
drop parameters have an influence on the heat transfer
3.4 Heat transfer coefficient
achieved.

1600
Heat transfer coefficient [W/m²/K]

Water flow:
Heat transfer coefficient [W/m²/K]

1400 450
Experiment
13.1 kg/h 400
1200 Fijimoto [5]
350 Müller / Jeschar [6]
9.9 kg/h
1000 300
250
800
200
600 150
5.7 kg/h ϑ = 550°C
400 100
w = 8m/s
50 D30 = 60µm
200
0
300 400 500 600 700 800
0,2 0,4 0,6 0,8 1
Surface temperature [°C]
Water impingement density [kg/m²/s]

Figure 9. Heat transfer coefficient

Figure 10. Heat transfer coefficient

From the time-dependent surface temperature plotted in

5. ACKNOWLEDGEMENTS
Fig. 7 the heat transfer coefficient is calculated using Eq. (6)
by taking the heat losses into account. In Fig. 9 the surface
The example from evaporation quenching is the scientific
temperature dependent heat transfer coefficient is plotted for
results of a research task, set by the Forschungskuratorium
the three water flows from Fig. 7. It can be seen that for a
Maschinenbau e.V. (FKM, Frankfurt) and handled by the
constant surface temperature the higher the water flow is, the
Institute of Fluid Dynamics and Thermodynamics of Otto-
higher the heat transfer coefficient is. For a constant water
von-Guericke University Magdeburg under the management
flow the lower the surface temperature is, the higher the heat
of Prof. E. Specht. The research task was financially
transfer coefficient is. The dependence of the heat transfer
supported by the Federal Ministry of Economics and
Technology (BMWi, Berlin) via the Arbeitsgemeinschaft
industrieller Forschungsvereinigungen e.V. (AiF, Köln),
(AiF-No. B11166)
6. REFERENCES
1. K. Dullenkopf, M. Willmann, S. Wittig, F. Schöne, M.
Stiegelmeier, C. Tropea, C. Mundo: Comparative Mass
Flux Measurements in Sprays using a Patternator and the
Phase-Doppler Technique. Part. Part. Syste. Charact. 15
(1998), 81-89
2. H. Boye, J. Schmidt: Einfluss von Oberflächen-
temperatur und Tropfenparametern auf den
Wärmeübergang bei der Sprühkühlung. Chem. Ing.
Tech. 70 (1998), 1177-1178
3. F. Puschmann, E. Specht, J. Schmidt: Evaporation
Quenching with Atomized Sprays. 3rd European Thermal
Sciences Conference 2000, 1071-1074
4. F. Puschmann, E. Specht, J. Schmidt: Local Distribution
of the Heat Transfer in Water Spray Quenching.
Continuous Casting, Wiley-VCH 2000, 101-107
5. Fujimoto, Hatta, Asakawa, Hasimoto: Predictable
Modelling of Heat Transfer Coefficient between
Spraying Water and a Hot Surface above the Leidenfrost
Temperature. ISIJ International 37 (5) (1997), 492-497
6. Müller, Jeschar: Untersuchung des Wärmeübergangs an
einer simulierten Sekundärkühlzone beim Strang-
gießverfahren. Archiv Eisenhüttenwesen 44 (1973), 589-
594
7. E. Specht, R. Jeschar: Heat Transfer in Continuous
Casting during Water-Spray Cooling. Heat and Mass
Transfer in Material Processing, Hemisphere Publishing
Corporation, Washington 1992, 535-547
8. R. Jeschar, C. Köhler, E. Specht, V. Heidt: Methoden
zur definierten Abkühlung metallischer Werkstoffe.
Gaswärme International 38 (1989), 223-229
9. H. Chaves, A. M. Kubitzek, F. Obermeier: Dynamic
Processes Occurring during the Spreading of Thin
Liquid Films produced by Drop Impact on Hot Walls.
Journal of Heat and Fluid Flow 20 (1999), 470 – 476
10. A. M. Kubitzek: Experimentelle Untersuchung des
Phasenübergangs beim Tropfenprall auf heiße Wände.
DLR-Forschungsbericht 97-21 (1997), DLR-Köln
11. A. Karl, A. Frohn: Experimental Investigation of
Interaction between Droplets and Hot Walls. Physics of
Fluids 12 (4) (2000), 785-796
12. A. Karl: Untersuchung der Wechselwirkung von
Tropfen mit Wänden oberhalb der Leidenfrost-
Temperatur, Shaker Verlag Aachen 1997