Nozzle Type

Typically full cone nozzles have the largest size droplet followed by flat spray nozzles and hollow cone nozzles. This trend applies equally to hydraulic and air assisted nozzles, however, air assisted nozzles provide very fine droplets that are smaller in size than traditional hydraulic nozzles. For a better description of the characteristics of various types of spray nozzles, click here to go to the nozzle index page.

Flow Rate
Flow rate has a direct effect on droplet size. An increase in flow rate will increase the droplet size; similarly, a decrease in flow rate will decrease droplet size. Example: A 150 gpm hollow cone nozzle at 10 psi has a larger droplet than a 100 gpm hollow cone at 10 psi. Similarly, a 50 gpm full cone nozzle at 7 psi has a smaller droplet size than a 120 gpm full cone nozzle at the same pressure.

Pressure (use our automated Spray Nozzle Flow Converter)

Pressure has an inverse effect on droplet size. An increase in pressure will reduce the droplet size, whereas a reduction in pressure will increase the droplet size. Example: A 1 gpm flat spray nozzle has a larger droplet at 30 psi than at 60 psi. Similarly, a 10 gpm full cone nozzle has a smaller droplet size at 40 psi than at 10 psi. Of the factors affecting flow rate, the most influential is pressure. Theoretically, the flow rate varies in correlation with the square root of the pressure, neglecting all other factors. Therefore, to compute flow rates other than those tabulated in the catalog, the following formula may be used (or use our automated flow calculator online by clicking here):

Q1 and P1 are the known flow rate and pressure. Q2 is the resulting flow rate for the desired pressure P2. If you need to calculate the pressure to achieve a specific flow rate, you can use a variation of the same formula:

P1 and Q1 are the known pressure and flow rate. P2 is the resulting pressure for the desired flow rate Q2.

Temperature
Temperature influences a liquid's viscosity, surface tension, and specific gravity, which in turn can affect spray nozzle performance.

Liquid Properties
Viscosity and surface tension increase the amount of energy required to atomize the spray. An increase in any of these properties will typically increase the droplet size. Virtually all droplet size data supplied from Lechler is based on spraying water under laboratory conditions. The effect of liquid properties should be understood and accounted for when selecting a nozzle for a process that is droplet size sensitive. Viscosity Viscosity is probably the most significant of all liquid properties because it can vary over an extreme range. Liquid viscosity resists surface formation. If the viscosity is great enough, a nozzle may produce a mass of filaments instead of a spray. Liquid viscosity is remarkably sensitive to temperature. Thus, liquid viscosity has a significant effect on all of the spray characteristics, Specific Gravity The main effect of the specific gravity of a fluid being sprayed is on the flow rate of the nozzle. The lower the specific gravity of a liquid, the higher the velocity through the nozzle, and vice versa. Thus, for lower specific gravity, the flow rate is larger than for liquid with a higher specific gravity at the same pressure.

Example: For a fluid with a specific gravity of 1.2 the flow rate would only be about 90% as compared to the flow of water which has a Specific Gravity of 1:

Surface Tension Surface tension is an important physical property affecting surface formation, and makes the liquid resist breaking into droplets. The main effect of surface tension is on the spray angle and droplet size of the sprayed fluid as well as the spray distribution.

Spray Angle
Spray angles have an inverse effect on drop size. An increase in the spray angle will reduce the droplet size, whereas a reduction in spray angle will increase the droplet size. Click Here to use our automated spray nozzle coverage and header layout calculator. Example: A 3 gpm flat spray nozzle with a 50 spray angle has a larger drop size than a 3 gpm flat spray nozzle with a 110 spray angle at the same operating pressure.

Impact
The impact or impingement of a spray is measurable, and should be taken into consideration in many applications. For more specific impact information consult with Lechler. As a general rule, the narrower the spray angle, the greater the impact over a given area.

Nozzle Wear
Nozzle wear is denoted by an increase in the nozzle flow rate and the subsequent deterioration of spray performance. A reduction in system operating pressure is often an indication of increased nozzle wear, especially when positive displacement pumps are used. Flat fan axial nozzles exhibit a narrowing of the spray pattern with wear. Other types of spray nozzles reveal a loss in spray uniformity within the spray pattern - though without a noticeable change in pattern size.

Nozzle Materials
Nozzles are available in many problem-solving materials. To spray corrosive fluids or for operation in corrosive environments, choose from a variety of chemically and thermally resistant materials, which include stainless steels, titanium, and Hastelloy; or corrosion resistant plastics, such as PVC, PP, PVDF, POM, and PTFE. To meet high wear and corrosion resistance requirements, common materials for nozzles include stainless steel, ceramic, tungsten carbide, Stellite, and silicon carbide. They are also available in precision injection molded materials such as PVDF.

Spray Nozzle Flow Rate Calculator

This calculator is meant to assist you with estimating the flow rate of a spray nozzle at pressures that aren't listed in a catalog or if you do not have a catalog readily available. Many nozzle companies use a part number that describes the spray angle and flow rate at 40 PSI. For instance, a "6520" is usually a 65 angle flat fan nozzle flowing ~2 GPM at 40 PSI. In the example below, the flow rate at 150 PSI is calculated to be ~3.87 GPM. Ultimately this calculator can be used to determine the required flow rate for a spray header, please see our Spray Coverage Calculator for assistance with determining the number of nozzles required. Directions: Change the blue INPUT numbers and Click the Update button. This equation is based upon the formula Q2 = Q1 x (Square Root of P2 / P1). Q1 and P1 are the known flow rate and pressure. Q2 is the resulting flow rate for the pressure in question P2. Q2a, Q2b and Q2c refer to the nozzle type in question.

INPUT Specific Gravity Known (Water = 1) Flow Sg

Known Pressure P1

Desired Pressure P2

Q1

Theoretical Flow Flat Fan Full Cone Full Cone Hollow Cone (<120 angle) (>120 angle) Solid Stream Q2a Q2b Q2c

GPM Gallons GPH

PSI

PSI

GPM GPH

GPM GPH

GPM GPH

per Hour Liters per Minute

LPM (Q1)

BAR (P1)

BAR(P2)

LPM (Q2a)

LPM (Q2b)

LPM (Q2c)

Note: There are factors besides specific gravity, such as liquid temperature, that effect flow rate. This data is based upon using water at 70F and is only meant as a reasonable guide for typical spray nozzle applications. It is

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Resource Center
Following is a listing of formulas and technical information related to our product lines. You can click-on phrases in the "table of contents" to jump right to a specific section. If there are specific formulas or technical data that you have questions about please let us know and we'll do our best to assist you.

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Spray Calculator Energy Savings Calculator Hydra-Cell Horsepower Required Calculator

Calculate flow rate at various pressures, including effect that specific gravity has on the flow rate Calculate the approximate energy savings by using a Sonic blower air knife system vs. Compressed Air Orifices, Nozzles and Inductor-type nozzles Calculate the horsepower required for a given Hydra-Cell Pump, by desired flow rate and discharge pressure

Documentation
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Spray Nozzle Related Glossary Terms and Technical Papers

Spray Nozzle Characteristics to Consider Nozzle Type Flow Rate Pressure Temperature Liquid Properties Spray Angle Impact Nozzle Wear Nozzle Material (Yellow Fields are Input Fields, Blue Fields are the Result)

Spray Nozzle Related Formulas

Flow Rate & Pressure Of the factors affecting flow rate, the most influential is pressure. Theoretically, the flow rate varies in correlation with the square root of the pressure, neglecting all other factors. Therefore, to compute flow rates other than those tabulated in the catalog, the following formula may be used: Q1 and P1 are the known flow rate and pressure. Q2 is resulting flow rate for the desired pressure P2.
Known Flow Rate Q1 Pressure for which Flow Rate is Desired Pressure Known P1 P2 Flow Rate at the Desired Pressure Q2

If you need to calculate the pressure to achieve a specific flow rate, you can use a variation of the same formula: P1 and Q1 are the known pressure and flow rate. P2 is the resulting pressure for the desired flow rate Q2.

Known Flow Rate Q1

Pressure for which Flow Rate is Desired Flow Rate Known P1 Q2

Pressure Required for Desired Flow Rate P2

Flow Rate & Specific Gravity The main effect of the specific gravity of a fluid being sprayed is on the flow rate of the nozzle. The lower the specific gravity of a liquid, the higher the velocity through the nozzle, and vice versa. Thus, for lower specific gravity, the flow rate is larger than for liquid with a higher specific gravity at the same pressure.
Known Flow Rate (based upon Specific Gravity of Liquid Water) Adjusted Flow Rate

Spray Nozzle Glossary

Following are descriptions of terms found throughout our website. You can click-on the alphabetized list to jump right to a particular definition. In some cases you can click-on glossary terms to get sent to web pages that describe those topics in more detail. If there are specific terms or questions that you have and they are not listed here, please let us know and we'll do our best to explain them to you. Click on a link below to jump down the page to that section Air Atomizing Spray Nozzles Hollow Cone Spray Nozzles Spray width Droplet size PVDF Material Flat Fan Spray Nozzles Solid Stream Nozzles Full Cone Spray Nozzles Spray angle

Air Atomizing Spray Nozzles: Use collision of metered air and liquid to provide the finest atomization of a liquid.

Internally Mixed: Air and liquid are mixed inside a nozzle body for low viscosity and clean fluids. Externally Mixed: Liquid and air mixing occurs outside of the nozzle for viscous and fluids with particulate. Droplet Size: The precision orifice(s) of spray nozzles are designed to break-up liquid into a multitude of droplets, usually for the purpose of increasing surface area, or concentrating liquid to create high impact force. Droplet size is frequently denoted by a mean of median diameter. The following seven nomenclatures are commonly used to describe droplet size. Each have different numerical values which vary widely. Mass Volume Median Diameter is the largest of all and number median diameter is the smallest. The differences between the various mean and median diameters provide a convenient way of specifying the "spread" of droplet sizes produced. If all the spray droplets had been uniform in size, the mean and median diameters would have been identical with the uniform size. Lechler measures droplet size with a PDPA system. Arithmetic Mean: The simple weighted average based on the diameters of all the individual droplets in the spray sample. Surface Mean: The diameter of a droplet whose surface area, if multiplied by the total number of droplets, will equal the total surface area of all the droplets in the spray sample. Sauter Mean: Also referred to as "volume surface mean", is the diameter of a droplet whose ration of volume to surface area is equal to that of the entire spray sample. Volume Surface Mean: Also referred to as, "sauter mean" is the diameter of a droplet whose ratio of volume to surface area is equal to that of the entire spray sample. Mass (Volume) Median Diameter: The diameter which divides the mass (volume) of spray into two equal halves. Surface Median Diameter: The diameter which divides the surface area of the droplets into two equal halves. Number Median Diameter: The diameter which divides the number of droplets into two equal halves. Flat Fan Spray Nozzles: Produce a sharply defined linear spray pattern and high impact force. Axial Flat Fan Nozzles: Straight through flow design having elliptical orifice. Deflector Flat Fan Nozzles: Use a precision machined deflector to sculpt a round orifice and solid stream pattern into a evenly distributed flat fan pattern. Full Cone Spray Nozzles: Uniform distribution of liquid across a circular or square area. Axial Full Cone Spray Nozzles: Straight through design having a "X" styled vane which provides uniform distribution of liquid. Tangential Full Cone Spray Nozzles: A right angle liquid flow design to provide uniform distribution without the need for internal vanes or swirl chambers. Hollow Cone Spray Nozzles: Used to provide a finely atomized flow having a pattern shaped like a ring. Axial Hollow Cone Nozzles: Straight through design having spiral grooves or inclined channels to produce a swirl and atomization. Tangential Hollow Cone Nozzles: Utilize a right angle supply of liquid. Swirl and atomization achieved via a swirl chamber. PVDF : Polyvinylidene Fluoride, a plastic material that lends itself to injection molding. As compared to stainless steel, PVDF resists erosion and corrosion better and is generally more compatible with a broad range of chemicals.

Solid Stream Spray Nozzles: Provide concentrated impact with prolonged pattern stability and integrity prior to liquid break-up. Spray Angle: Also referred to as spray width, it is typically measured near the nozzle orifice. As the spray distances increase, the measure of the spray pattern length/diameter become significantly less accurate and dependant upon gravity and ambient conditions such as air friction losses and other external influences affecting the spray pattern trajectory. Spray Width: Related to the spray angle, it is typically measured near the nozzle orifice. As the spray distances increase, the measure of the spray pattern length/diameter become significantly less accurate and dependant upon gravity and ambient conditions such as air friction losses and other external influences affecting the spray pattern trajectory. Surface Tension: This physical property is related to the resistance of the sprayed liquid to break-up into droplets. The primary effects of surface tension are spray angle, droplet size and spray distribution. Leidenfrost phenomenon: A cushion of vapor repels liquids from surfaces the temperature of which is above their boiling point. See illustration below:

A rocket engine uses a nozzle to accelerate hot exhaust to produce thrust as described by Newton's third law of motion. The amount of thrust produced by the engine depends on the mass flow rate through the engine, the exit velocity of the flow, and the pressure at the exit of the engine. The value of these three flow variables are all determined by the rocket nozzle design. A nozzle is a relatively simple device, just a specially shaped tube through which hot gases flow. Rockets typically use a fixed convergent section followed by a fixed divergent section for the design of the nozzle. This nozzle configuration is called a convergent-divergent, or CD, nozzle. In a CD rocket nozzle, the hot exhaust leaves the combustion chamber and converges down to the minimum area, or throat, of the nozzle. The throat size is chosen to choke the flow and set the mass flow rate through the system. The flow in the throat is sonic which means the Mach number is equal to one in the throat. Downstream of the throat, the geometry diverges and the flow is isentropically expanded to a supersonic Mach number that depends on the area ratio of the exit to the throat. The expansion of a supersonic flow causes the static pressure and temperature to decrease from the throat to the exit, so the amount of the expansion also determines the exit pressure and temperature. The exit temperature determines the exit speed of sound, which determines the exit velocity. The exit velocity, pressure, and mass flow through the nozzle determines the amount of thrust produced by the nozzle.

On this slide we derive the equations which explain and describe why a supersonic flow accelerates in the divergent section of the nozzle while a subsonic flow decelerates in a divergent duct. We begin with the conservation of mass equation: mdot = r * V * A = constant where mdot is the mass flow rate, r is the gas density, V is the gas velocity, and A is the crosssectional flow area. If we differentiate this equation, we obtain: V * A * dr + r * A * dV + r * V * dA = 0 divide by (r * V * A) to get: dr / r + dV / V + dA / A = 0 Now we use the conservation of momentum equation: r * V * dV = - dp and an isentropic flow relation: dp / p = gam * dr / r where gam is the ratio of specific heats. This is Equation #10 on the page which contains the derivation of the isentropic flow relations We can use algebra on this equation to obtain: dp = gam * p / r * dr and use the equation of state p/r=R*T where R is the gas constant and T is temperature, to get: dp = gam * R * T * dr gam * R * T is the square of the speed of sound a: dp = (a^2) * dr Combining this equation for the change in pressure with the momentum equation we obtain: r * V * dV = - (a^2) * dr V / (a^2) * dV = - dr / r - (M^2) * dV / V = dr / r using the definition of the Mach number M = V / a. Now we substitute this value of (dr /r) into the mass flow equation to get:

- (M^2) * dV / V + dV / V + dA / A = 0 (1 - M^2) * dV / V = - dA / A This equation tells us how the velocity V changes when the area A changes, and the results depend on the Mach number M of the flow. If the flow is subsonic then (M < 1) and the term multiplying the velocity change is positive (1 - M^2 > 0). Then an increase in the area (dA > 0 ) produces a negative increase (decrease) in the velocity (dV < 0). For our CD nozzle, if the flow in the throat is subsonic, the flow downstream of the throat will decelerate and stay subsonic. So if the converging section is too large and does not choke the flow in the throat, the exit velocity is very slow and doesn't produce much thrust. On the other hand, if the converging section is small enough so that the flow chokes in the throat, then a slight increase in area causes the flow to go supersonic. For a supersonic flow (M > 1) the term multiplying velocity change is negative (1 M^2 < 0). Then an increase in the area (dA > 0) produces an increase in the velocity (dV > 0). This is exactly the opposite of what happens subsonically. Why the big difference? Because in supersonic (compressible) flows, both the density and the velocity are changing as we change the area in order to conserve mass. For subsonic (incompressible) flows, the density remains fairly constant, so the increase in area produces a decrease in velocity to conserve mass. But in supersonic flows, there are two changes; the velocity and the density. The equation: - (M^2) * dV / V = dr / r tells us that for M > 1, the change in density is much greater than the change in velocity. To conserve both mass and momentum in a supersonic flow, the velocity increases and the density decreases as the area is increased. There has been research and some experiments conducted on alternate nozzle designs. A plug nozzle has a solid surface along the centerline of the nozzle and a free surface along the outside. Plug nozzles can match exit pressure over a larger range of flight conditions than a CD nozzle, but tend to be heavier than a CD nozzle. The aerospike engine used a rectangular plug nozzle and multiple combustion chambers. These types of nozzles are still in the research phase and are not yet used on commercial rockets. Most full scale rockets use the rocket exhaust nozzle as part of the stability and control system. The nozzle can be pivoted, or gimbaled, to re-direct the thrust vector. The thrust force can then be used to maneuver the rocket in flight. Guided Tours Rocket Thrust: Propulsion System:

Activities: Gas Pressure Activity: Grade 10-12

Related Sites: Rocket Index Rocket Home Exploration Systems Mission Directorate Home