In this theoretical review study included Air-Jet Textured Yarn spinning technology (ATY); its importance, formation mechanism principle, yarns used, and general properties were explained in detail, supported by images and tables from various sources. Moreover, the specific ATY yarn process parameters required for ATY yarn production and the quantitative values ​​of these process parameters were presented. Finally, the effects of ATY yarn types, and various ATY yarn process parameters on the thermal comfort, physical, and mechanical properties of textile-based woven, and knitted fabrics were explained. According to the results included ATY yarn production machines produced by DuPont and Heberlain Companies have generally used for the production of ATY yarns nowadays. Moreover, multi-jet systems (4 jets) called the Taslan have widely used because they affect the air pressure values, and air-flow regime more homogeneously in various yarn formation axes. Effective technical parameters for ATY yarn production are jet (nozzle) type, jet (nozzle) angle (°), overfeed ratio, amount of compressed air-flow (volumetric air-flow ratio), number of air-jets (nozzles), air-jet inner diameter (mm), production speed (m/min), heater and cooling plate temperatures (°C), times, lengths (mm), inner diameters, pre-tension values, types, and cross-sections of yarns and filaments, wetting of the yarn and the elasticity modulus of the deflection ball of the yarn (N/mm²). Additionally, FDY structure, yarn count (dtex)/filament count from 80/24 to 1666/1000, overfeed ratio value from 5.5 to 36, air pressure value from 7 bar to 10 bar, production speeds from 300 m/min to 500 m/min, a draft ratio value of between 1.75 and 2.19, and a temperature value of 180 °C to 200 °C are generally used in the production of ATY yarns. Texturing property (bulky volume), instability, and mass loss increase, but tensile strength decreases as air pressure increases. These effects are more evident in fine yarn counts (dtex). Tensile strength increases, but instability, and mass loss decrease as the texturing speed increases. Water consumption has no effect on the physical, mechanical, and thermal comfort properties of both woven, and knitted fabrics with ATY yarn structures. POY and FDY structured PET, PA 6, PA 6.6, PP, PI, CV, CO, CMD, PPD-T, and EA yarns are used in the production of ATY yarns. ATY yarns are widely used in home textiles, clothing, airbags, carpets, and upholstery fabrics. The multi-lobed section PET ratio should be high for high bursting strength, tensile strength, air permeability, maximum breaking force, texturing property (bulky volume) and linear density of the yarn values, high shear strength, maximum percent elongation at break, thermal conductivity, pilling resistance. The ratio of CMD, CV, PA 6, or PA 6.6 should be high for water vapor permeability values. The CO ratio should be high for high thermal resistance. The PET ratio should be high for high abrasion resistance values. Shear strength, maximum percent elongation at break, elastic recovery behavior, and abrasion resistance increase as the EA ratio increases. ATY yarns have lower tensile strength, maximum breaking force, maximum percent breaking elongation, breaking work, and abrasion resistance values compared to ring, and OE rotor yarns (except DTY), respectively. The issue of recycling is extremely important for the sustainability of the global textile industry in the future. For this important issue, textile waste must be classified, collected, and evaluated. Moreover, optimization of various experimental production process parameters should be ensured in order to preserve the mechanical properties of blended yarns, especially CO/PET, and CO/PA yarn structures, by reducing chemical, water, energy, and labor costs.

Keywords: Air-Jet Textured Yarn Spinning Technology (ATY), process parameters, yarns, fabrics, general properties

In this theoretical review study included Air-Jet Textured Yarn spinning technology (ATY); its importance, formation mechanism principle, yarns used, and general properties were explained in detail, supported by images and tables from various sources. Moreover, the specific ATY yarn process parameters required for ATY yarn production and the quantitative values of these process parameters were presented. Finally, the effects of ATY yarn types, and various ATY yarn process parameters on the thermal comfort, physical, and mechanical properties of textile-based woven, and knitted fabrics were explained. This study aimed to summarize the information of various experimental studies on Air-Jet Textured yarn spinning technology (ATY), to ensure the optimization of the production process parameters of ATY yarn production according to yarn types, and to produce home textiles such as casual clothes, airbags, and upholstery fabrics where thermal comfort will be at the forefront. It has been prepared for the technical optimization of its effects on various structural, physical, and mechanical properties of woven or knitted fabrics to be produced for their applications.

Importance, formation mechanism principle, yarns used, and general properties for Air-Jet Textured Yarn Spinning Technology (ATY)

Air-Jet Textured Yarn spinning technology (ATY) was produced with using various nozzle profiles that create a supersonic, turbulent, and non-uniform air environment, the yarn is used in the heater and cooling plates by entangling and twisting it (with the vortex effect) thanks to the air-flow (water vapor - wetting) applied to the fibers that form the Air-Jet Textured yarn and turning it into a looped structure (with the vortex effect). It is the formation of a stable yarn by drawing it within a certain temperature range (first heating, and after cooling (fixing)) depending on the yarn type.^{1,2,4–7,9,14,15} ATY started with the patent of the DuPont company in 1951 and was also developed by Mirlan in Czechoslovakia. It started with the development of Jet. After the 2000s, it has continued to develop until today with significant technological developments especially in jet (nozzle) profiles. The most important design criterion in ATY is jet. (it is number of jet (nozzle)). Air pressure is created thanks to the jet (nozzle) profile. The developments in ATY technology actually depend on the jet profile due to this situation. The first ATY technology developed by DuPont had a production speed of 50 m/min and compressed air with an air-flow of over 20 m³/hour.

Although the DuPont company increased the production speed up to 350 m/min over time with the ATY technology it developed, in 1978 the Heberlain company introduced a new product, called the T series, with a completely unique jet (nozzle) design, at a production speed of 500 m/min and consuming less air compared to the DuPont company. It developed the jet (nozzle). Later, in 1997, the Heberlain company introduced a new jet called the S series, and the production speed of this jet was 800 m/min. The reason for this high production ratio was that the jet design had multiple number of jets (nozzles). Thus, ATY yarns are exposed to more and higher velocity turbulent air-flows. This increases the looped structure of ATY yarn. So, it ensures that it is a textured (bulky volume) yarn. Moreover, this new multiple jet (nozzle) is known as Taslan. This new jet with a multiple jet (nozzle) structure developed by the Heberlain company had higher performance compared to the jet structure called Taslan, which DuPont, and Hemajet also developed over time.¹ The effective technical parameters for the developed ATY yarn production are jet (nozzle) type, jet (nozzle) angle (°), overfeed ratio, amount of compressed air-flow (volumetric air-flow ratio), number of air-jet (nozzle), air-jet (nozzle) inner diameter (mm), production speed (m/min), heater and cooling plate temperatures (°C), times, lengths (mm), inner diameters, pre-tension values, types and cross-sections of yarns and filaments, wetting of the yarn and the elastic modulus of the deflection ball of the yarn (N/mm²), tensile strength of the yarn (MPa), number of the yarn (dtex), and its effects on the dimensional stability of the yarn.^1–18,22 Even though the entanglement behavior of the fibers forming ATY yarn in the supersonic air-flow environment has been examined by various scientists, a complete technical explanation has not been found. When the jets (nozzles) of DuPont and Heberlain companies, which are the jet (nozzle) manufacturers that they generally provide the production of the most commonly used commercial ATY yarns today. It has been determined that bar compressed air is used, the air-flow regime is supersonic, turbulent, and asymmetric, the air-flow speed is non-uniform and creates shock waves.⁸ It has been observed that these shock waves first cause the separation of the fibers from each other in the fibers forming the ATY yarn, and after their displacement in the longitudinal direction (deviation from the fiber axis). Thus, ensuring the ATY yarns have a looped structure (Air-Jet Texturing).¹ The properties of ATY yarns are higher texture properties (bulky volume) in woven and knitted fabrics, it provides better touch and comfort properties in the fabrics, and provides higher rubbing fastness, elasticity modulus, pilling resistance, a rough surface, and lower tensile strength values thanks to their friction coefficients.^2,4,14–18 Porosity and cover factor are the most important factors affecting the moisture and thermal properties of woven and knitted fabrics.^10,11 ATY yarns with hollow filaments are widely used thanks to their permeability adsorption, and fast-drying properties especially in sportswear applications. In addition; DTY, ATY, ITY, and BCY yarns are widely used in sportswear applications thanks to their high texturing properties (bulky volume). Moreover; factors such as yarn type, yarn structure, yarn filament count, yarn and filament cross-sections, yarn count, pore size and number, warp density, weft density, thickness, weight, fabric construction are also effective factors on the moisture and thermal properties for their fabrics.^10–18 As the fixation temperature of a twisted ATY yarn used as a carpet yarn increases, its static recycling also increases in the autoclave process.¹² The loop size, instability, and loop structure increase in ATY yarns as the pressure value of the applied air pressure increases. Thus, it means a higher amount of textured ATY yarn. Moreover, the tensile strength, and maximum percent elongation of ATY yarns decrease as the air pressure increases.^1,2 Another observation on this subject is about the relationship between the migration movements of the fibers and air pressure. According to this view that as the air pressure increases, the number of fibers with large loop sizes forming the ATY yarn decreases, the irregularity of the fibers decreases, and the dimensional stability of the ATY yarn is better.¹ POY and FDY structured PET, PA 6, PA 6.6, PP, PI, CV, CO, CMD, PPD-T, and EA yarns are used in the production of ATY yarns.^1,2,4–18 The water consumption amount of the jet (nozzle) is 1 liter/hour for 1 bar pressure.^6,7 Jet (nozzle) geometry, yarns, and filaments; geometry, diameter, and number of jets (nozzles) were simulated and proven to be the most effective design criteria on hairiness, loop size and number, instability, tensile strength, maximum breaking force and maximum percent elongation at break.³ The ATY Yarn production theoretical view was presented in Figure 1.⁷

Figure 1 The ATY yarn production theoretical view.⁷

The technical internal structure of the single jet (nozzle) used in ATY yarn production was presented in Figure 2.⁵

Figure 2 The technical internal structure of the single jet (nozzle) used in ATY yarn production.⁵

The real views of the single jet (nozzle) used in ATY yarn production were presented in Figure 3.⁸

Figure 3 The real views of the single jet (nozzle) used in ATY yarn production.⁸

Rice, trilobal, and circular, respectively (from top to bottom) for the cross-sectional views of ATY yarns were presented in Figure 4.²

Figure 4 Rice, trilobal, and circular, respectively (from top to bottom) for the cross-sectional views of ATY yarns.²

Proses production parameters for yarn production of Air-Jet Textured Yarn Spinning Technology (ATY)

Various yarn types, yarn structures (POY or FDY), yarn counts (dtex), filament numbers, overfeed ratios (%), air pressure values ​​(bar), texturing speeds (m/min), drawing ratios, and heating plate temperatures (°C)  are important for ATY yarn production as their process production parameters.

Technical summary information of various experimental studies on the production process parameters of ATY yarns produced with Air-Jet Textured Yarn spinning technology (ATY) was presented in Table 1.^{1,2,4–10,13,15,16}

Structural, physical, and mechanical properties for fabric forms of Air-Jet Textured Yarn Spinning Technology (ATY)

ATY yarn process production parameters such as various yarn types, yarn structures (POY or FDY), yarn counts (dtex), filament numbers, overfeed ratios (%), air pressure values ​​(bar), texturing speeds (m/min), drawing ratios, and heating plate temperatures (° C) effect on various physical, mechanical, and thermal comfort properties of woven and knitted fabrics produced from DTY, ring, and OE rotor yarns, mostly ATY yarns were interpreted comparatively and technically in Table 2.

Technical summary information of various experimental studies on general technical conclusions for various experimental studies of ATY yarns, and fabrics produced with Air-Jet Textured Yarn spinning technology (ATY) was presented in Table 2.^{1,2,4–13,16–18}

Sustainability, and future trends of Air-Jet Textured Yarn Spinning Technology (ATY)

Raw materials (especially natural, regenerated, or synthetic-based yarns) go through many long-term production processes to be transformed into final products (non-woven, woven, or knitted fabrics) in the global textile industry. While raw materials (especially for yarns) are used in high quantities in these production processes, they can be produced with high chemical, water, energy (such as washing, drying, and ironing), and labor costs.^19–21 Environmental interactions, and recycling of products due to climate change the importance of transformation is high and varies depending on the raw material in these production processes. This has led to various theoretical, and experimental studies on the subject of recycling.^19–23 Because sustainability can be achieved as long as recycling can be achieved.²⁰ In addition, textile waste must be classified, collected, and evaluated. Production efficiency should be kept maximum by ensuring that natural raw materials (especially natural-based yarns) can be reproduced with clean technologies, and the process parameters in the production processes are optimized. Moreover, the amount of waste losses should also be noted.¹⁹ For this purpose, high-level and multiple repetition filtration methods should be applied in the production processes of final products. Moreover, the use of biological, and environmentally friendly auxiliary chemicals, which require low production time, water, and energy consumption, needs to be increased.²⁰ Process parameters such as yarn type, yarn count (dtex), drawing system, drawing roller number, geometry, drawing ratio, and production speed are extremely effective in recycling processes for yarns.^{14,19,21–23} They have been carried out on both pure, and blended yarn structures of CO, RA, Malina, PA, and PET yarns for their experimental studies on recycling.^14,19–23 Especially, the mechanical properties of ATY, OE rotor, and ring spinning technologies are studied.^{14,19.,21–23} According to the Sustainable Development Goals (SDG) aims that they can be to transform natural-based raw materials into very high amounts of final products by 2030 in the global textile industry.²⁰ The mechanical properties of CO/PET blended ring yarns were at lower values. In addition, the least impact on the mechanical properties of CO ring yarn was observed at the Ne 10 yarn count. Moreover, as the amount of waste increased, the mechanical properties of the yarn decreased.¹⁹ The mechanical properties of PET ring yarns were decreased.²³ There was a minimum loss in mechanical properties when OE rotor yarns with CO yarn structure were recycled at a ratio of 80% but as the recycling rate increased, the quality, cost, and mechanical properties of the yarn decreased. Moreover, yarn defects were increased.²¹

According to the results included ATY yarn production machines produced by DuPont and Heberlain Companies have generally used for the production of ATY yarns nowadays. Moreover, multi-jet systems (4 jets) called the Taslan have widely used because they affect the air pressure values, and air-flow regime more homogeneously in various yarn formation axes. Effective technical parameters for ATY yarn production are jet (nozzle) type, jet (nozzle) angle (°), overfeed ratio, amount of compressed air-flow (volumetric air-flow ratio), number of air-jets (nozzles), air-jet inner diameter (mm), production speed (m/min), heater and cooling plate temperatures (°C), times, lengths (mm), inner diameters, pre-tension values, types, and cross-sections of yarns and filaments, wetting of the yarn and the elasticity modulus of the deflection ball of the yarn (N/mm²). Additionally, FDY structure, yarn count (dtex)/filament count from 80/24 to 1666/1000, overfeed ratio value from 5.5 to 36, air pressure value from 7 bar to 10 bar, production speeds from 300 m/min to 500 m/min, a draft ratio value of between 1.75 and 2.19, and a temperature value of 180 °C to 200 °C are generally used in the production of ATY yarns. Texturing property (bulky volume), instability, and mass loss increase, but tensile strength decreases as air pressure increases. These effects are more evident in fine yarn counts (dtex). Tensile strength increases, but instability, and mass loss decrease as the texturing speed increases. Water consumption has no effect on the physical, mechanical, and thermal comfort properties of both woven, and knitted fabrics with ATY yarn structures. POY and FDY structured PET, PA 6, PA 6.6, PP, PI, CV, CO, CMD, PPD-T, and EA yarns are used in the production of ATY yarns. ATY yarns are widely used in home textiles, clothing, airbags, carpets, and upholstery fabrics. The multi-lobed section PET ratio should be high for high bursting strength, tensile strength, air permeability, maximum breaking force, texturing property (bulky volume) and linear density of the yarn values, high shear strength, maximum percent elongation at break, thermal conductivity, pilling resistance. The ratio of CMD, CV, PA 6, or PA 6.6 should be high for water vapor permeability values. The CO ratio should be high for high thermal resistance. The PET ratio should be high for high abrasion resistance values. Shear strength, maximum percent elongation at break, elastic recovery behavior, and abrasion resistance increase as the EA ratio increases. ATY yarns have lower tensile strength, maximum breaking force, maximum percent breaking elongation, breaking work, and abrasion resistance values compared to ring, and OE rotor yarns (except DTY), respectively. The issue of recycling is extremely important for the sustainability of the global textile industry in the future. For this important issue, textile waste must be classified, collected, and evaluated. Moreover, optimization of various experimental production process parameters should be ensured in order to preserve the mechanical properties of blended yarns, especially CO/PET, and CO/PA yarn structures, by reducing chemical, water, energy, and labor costs.

None.

The author declares that there is no conflict of interest.

None.

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