We experimentally study the formation and evolution of threads containing more viscous liquids surrounded by less viscous, immiscible liquids through hydrodynamic focusing in square microchannels. Over a large range of viscosities and interfacial tensions, five characteristic regimes of flow behavior are identified: threading, jetting, dripping, tubing, and displacement. We locate the boundaries between these regimes on a flow map based on the capillary number of each fluid. In the jetting and the dripping regimes, the droplet size is measured and related to fluid properties, flow parameters, and geometry. The critical thread length before jetting droplets and the critical length of a viscous tail before breakup in dripping are also examined. This study classifies and defines regimes of thread instabilities that can be used to produce supra-and subchannel size viscous droplets in an elementary microfluidic geometry.

Liquid/gas flows are experimentally investigated in 200 and 525 m square microchannels made of glass and silicon. Liquid and gas are mixed in a cross-shaped section in a way to produce steady and homogeneous flows of monodisperse bubbles. Two-phase flow map and transition lines between flow regimes are examined. Bubble velocity and slip ratio between liquid and gas are measured. Flow patterns and their characteristics are discussed. Local and global dry out of the channel walls by moving bubbles in square capillaries are investigated as a function of the flow characteristics for partially wetting channels. Two-phase flow pressure drop is measured and compared to single liquid flow pressure drop. Taking into account the homogeneous liquid fraction along the channel, an expression for the two-phase hydraulic resistance is experimentally developed over the range of liquid and gas flow rates investigated.

This Letter reports experimental results on the coalescence of two liquid drops driven by surface tension. Using a high speed imaging system, we studied the early-time evolution of the liquid bridge that is formed upon the initial contact of two liquid drops in air. Experimental results confirmed the scaling law that was proposed by Eggers et al. based on a simple and yet elegant physical argument. We found that the liquid bridge radius r b follows the scaling law r b ϰt 1/2 in the inertial regime. Further experiments demonstrate that such scaling law is robust when using fluids of different viscosities and surface tensions. The prefactor of the scaling law, r b /t 1/2 , is shown to be ϰR 1/4 , where R is the inverse of the drop curvature at the point of contact. The dimensionless prefactor is measured to be in the range of 1.03-1.29, which is lower than 1.62, a prefactor predicted by the numerical simulation of Duchemin et al. for inviscid drop coalescence.

This Brief Report presents experimental and computational results on bubble formation in microfluidic devices. Bubbles are generated at the right-angle intersection of four identical square microchannels. When the pressure gradient generated by the liquid flow dominates the pressure gradient generated by gas flow, the length of the produced confined bubbles follows a law based on the channel size and fluid volume fraction. This bubble production technique was used to produce monodisperse aqueous foam in two-dimensional and three-dimensional microchannels.

We study the folding instability of a viscous thread surrounded by a less viscous miscible liquid flowing from a square to a diverging microchannel. Because of the change in the flow introduced by the diverging channel, the viscous thread minimizes viscous dissipation by oscillating to form bends rather than by simply dilating. The folding frequency and the thread diameter can be related to the volume flow rates and thus to the characteristic shear rate. Diffusive mixing at the boundary of the thread can significantly modify the folding flow morphologies. This microfluidic system enables us to control the bending of the thread and to enhance mixing between liquids having significantly different viscosities.