Mechanism and control of ultra-fine film jet atomization driven by forced breakup of interfacial bubbles

Ultra-fine atomization (droplet diameter 0.1–10 μm) is critically important in precision manufacturing and biopharmaceuticals. However, conventional atomization techniques still face challenges when handling high-viscosity liquids or pursuing high-output stability. This work studied a novel thin-film jet atomization mechanism based on “forced bubble breakup at interfaces.” By establishing an experimental platform combined with high-speed photography and laser diffraction techniques, this paper quantitatively investigates the effects of operating pressure, micro-orifice geometric parameters (angle, diameter), and tube material properties on atomization performance (Sauter mean diameter D32 and gas-to-liquid mass ratio GLR). Experimental results indicate that increasing gas pressure significantly reduces D32, but the fine droplet size stabilizes after exceeding a critical threshold of 0.35 MPa. Regarding geometry, a micro-orifice angle of 45° exhibits optimal atomization fineness, while the influence of micro-orifice diameter on D32 is relatively limited. Furthermore, to address the high energy consumption of rigid PFA (Perfluoroalkoxy Alkane) tubes, this paper proposes an innovative dual-silicone tube parallel design, successfully reducing the GLR by 51% while maintaining excellent atomization performance. This study reveals the non-linear regulation laws of bubble–jet interactions, providing important theoretical basis and a guiding framework for the structural optimization and energy-saving design of industrial ultra-fine atomization equipment.