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In the department "Multiphase Flow, Heat and Mass Transfer" the research activities are concentrated on processes for the production, handling and conditioning of disperse phases (e.g. powders, particles or droplets) in liquid or solid form. In particular, the analysis of the interaction processes at the phase interfaces of particles with their fluid environment, which are characterized by multi-phase impulse, heat and mass transfer processes, is in the foreground.

Essential applications of the investigations in this area are processes with spray and jet flows from the production and handling of metallic and ceramic powders and thermal process technology.

Basic investigations in multiphase flow systems and practice-oriented questions of application in e.g. multiphase cooling processes in the context of heat treatment of metals are treated.

For the scientific objectives of the department "Multiphase Flow", laser-optical measuring methods of fluid and particle technology are developed and applied as tools in combination with numerical simulation calculations and modelling. Based on this, measures for process design and optimization are derived and verified.


Analyses of processes are offered within the scope of research projects, but also as a service:

Analysis of multiphase flow systems

  • Laser light-section visualization (LLS)
  • Schlieren optics
  • High Speed Videography (HSP)
  • Concentration measurement
  • Measurement of particle size, particle velocity and particle temperature distributions


Atomization and spray characterization

  • Analysis of liquid decay
  • Spray characterization
  • Spray cooling, spray coating, spray compaction


Powder analyses

  • Particle size and shape
  • Flowability


Modelling and simulation of multiphase systems

  • multiphase flows
  • Fluid atomization and spray propagation
  • Quenching and cooling processes
  • Evaporation, condensation and solidification processes


Test facilities for particle-loaded multiphase flows are used for:

  •     atomization of fluids, melts and solutions, suspensions and emulsions
  •     Transport of particles
  •     Dispersion, separation and conditioning of particles
  •     Laser Doppler and Phase Doppler Anemometry (LDA / PDA)
  •     Particle Image Velocimetry (PIV)
  •     High Speed Particle Pyrometry (HSP)
  •     diffraction spectrometry (BSM)
  •     Hot-wire anemometry (CTA)
  •     Visualization: Short term videography, schlieren optics systems, laser light section system



The scientific work of the department "Multiphase Flow" currently focuses on the following areas:


Detection of micro processes and structures during the dispersion of fluids, emulsions, suspensions and melts

  •     Dispersion and disintegration processes during atomization
  •     Emulsification processes of complex rheological fluids
  •     Microfluidics and emulsification of fluids and melts in porous structures and membranes
  •     Inline quality control of emulsions and cooling lubricants


Generation of powders and semi-finished products from mineral, metallic and polymer melts


  • Concepts for atomization units for energy-efficient processes and adapted product properties of powders in the micro- and nanometer range
  • Development of thermal and kinetic boundary conditions for the derivation of adapted process control strategies
  • Powder production in spray processes, process technology of spray compacting


Process analysis and optimization in thermal process technology

  •     Analysis of flow and heat transfer conditions on complex components in gas and liquid quenching processes
  •     Development of spatially and temporally controlled heat transfer scenarios
  •     Cooling and quenching with spray and jet systems in liquids and gases
  •     Derivation of strategies to avoid or compensate for component distortion in the manufacturing process
  •     Energy efficiency in thermal process technology


Development of numerical models for the description of multiphase flows (M-CFD Multiphase Computational Fluid Dynamics)

  •     Models for the description of topology changes in multiphase flows (atomization, drop decay and coalescence, ...)
  •     Lattice Boltzmann method for the analysis of multiphase flows
  •     Coupling of thermal models and phase field modelling
  •     Modelling of the evaporation process (flow boiling)
  •     Modelling for spatially and temporally resolved dispersion flows (Sharp Interface Model)
  •     Dynamic Flow Sheet Simulation of particulate processes (solid process engineering)
  •     OpenFOAM extensions for M-CFD
  •     Coupling of CFD and PBM (population balances)
  •     Turbulent Combustion Modelling
  •     Particles from the gas phase, modelling and simulation
  •     Modelling of ultrasonic applications

Projects of Multiphase Flow, Heat and Mass Transfer

VerA distortion compensation in aluminum die casting process chains

The aim of the VerA project is to develop a method of compensating for process-induced residual stresses in aluminum die casting during production. The complete process chain from casting to heat treatment is considered.

The motivation of the project is the economical production of large-area, thin-walled die cast integral components that meet the lightweight construction requirements of the automotive industry. Currently, cost-intensive measures such as straightening operations are necessary to compensate for distortion. In the process chain under consideration, from casting to heat treatment, locally controlled quenching is used to influence distortion and internal stresses during heat treatment. Quenching is performed by adaptive spray field systems. When adapting the spray field, component-specific data from process monitoring are used so that warpage can be compensated for by optimum local cooling rates.

This project was funded by the German Federation of Industrial Research Associations (AiF).

Working on the project: IWT-Verfahrenstechnik, IWT-Leichtbauwerkstoffe, IFAM

Funding: BMWi-AiF

Duration: 01.04.2022 - 30.09.2024

M.Sc. Lisa Husemann
Tel.: +49421 218 51325

Dilyan Kamenov
Tel.: +49421 218 51231
E-Mail: d.kamenov(at)