Matching Items (86)
Filtering by
- All Subjects: Mechanical Engineering
- All Subjects: engineering
- Creators: Herrmann, Marcus
- Creators: Rykaczewski, Konrad
Description
Thermal management of electronics is critical to meet the increasing demand for high power and performance. Thermal interface materials (TIMs) play a key role in dissipating heat away from the microelectronic chip and hence are a crucial component in electronics cooling. Challenges persist with overcoming the interfacial boundary resistance and filler particle connectivity in TIMs to achieve thermal percolation while maintaining mechanical compliance. Gallium-based liquid metal (LM) capsules offer a unique set of thermal-mechanical characteristics that make them suitable candidates for high-performance TIM fillers. This dissertation research focuses on resolving the fundamental challenges posed by integration of LM fillers in polymer matrix. First, the rupture mechanics of LM capsules under pressure is identified as a key factor that dictates the thermal connectivity between LM-based fillers. This mechanism of oxide “popping” in LM particle beds independent of the matrix material provides insights in overcoming the particle-particle connectivity challenges. Second, the physical barrier introduced due to the polymer matrix needs to be overcome to achieve thermal percolation. Matrix fluid viscosity impacts thermal transport, with high viscosity uncured matrix inhibiting the thermal bridging of fillers. In addition, incorporation of solid metal co-fillers that react with LM fillers is adopted to facilitate popping of LM oxide in uncured polymer to overcome this matrix barrier. Solid silver metal additives are used to rupture the LM oxide, form inter-metallic alloy (IMC), and act as thermal anchors within the matrix. This results in the formation of numerous thermal percolation paths and hence enhances heat transport within the composite. Further, preserving this microstructure of interconnected multiphase filler system with thermally conductive percolation pathways in a cured polymer matrix is critical to designing high-performing TIM pads. Viscosity of the precursor polymer solution prior to curing plays a major role in the resulting thermal conductivity. A multipronged strategy is developed that synergistically combines reactive solid and liquid fillers, a polymer matrix with low pre-cure viscosity, and mechanical compression during thermal curing. The results of this dissertation aim to provide fundamental insights into the integration of LMs in polymer composites and give design knobs to develop high thermally conducting soft composites.
ContributorsUppal, Aastha (Author) / Rykaczewski, Konrad (Thesis advisor) / Wang, Robert (Thesis advisor) / Kwon, Beomjin (Committee member) / Choksi, Gaurang (Committee member) / Phelan, Patrick (Committee member) / Arizona State University (Publisher)
Created2022
Description
Identifying and tracking the location of the fluid interface is a fundamental aspect of multiphase flows. The Volume of Fluid (VOF) and Level Set methods are widely used to track the interface accurately. Analyzing the liquid structures such as sheets, ligaments, and droplets helps understand the flow physics and fluid breakup mechanism, aids in predicting droplet formation, improves atomization modeling and spray combustion. The thesis focuses on developing a new method to identify these liquid structures and devise a sphere model for droplet size prediction by augmenting concepts of linear algebra, rigid body dynamics, computational fluid mechanics, scientific computing, and visualization. The first part of the thesis presents a new approach to classify the fluid structures based on their length scales along their principal axes. This approach provides a smooth tracking of the structures' generation history instead of relying on high-speed video imaging of the experiment. A droplet is observed to have three equal length scales, while a ligament has one and a sheet has two significantly larger length scales. The subsequent breakup of ligaments and droplets depends on the atomizer geometry, operating conditions, and fluid physical properties. While it's straightforward to apply DNS and estimate this breakup, it is proven to be computationally expensive. The second part of the thesis deals with developing a sphere model that would essentially reduce this computational cost. After identifying a liquid structure, the sphere model utilizes the level set data in the domain to quantify the structure using spheres. By using the evolution information of these spheres as they separate from each other, the subsequent droplet size distribution can be evaluated.
ContributorsKashetty, Sindhuja (Author) / Herrmann, Marcus (Thesis advisor) / Wells, Valana (Committee member) / Kim, Jeonglae (Committee member) / Arizona State University (Publisher)
Created2021
Description
This paper documents the design, analysis, and construction of a towing tank suitable for experimental studies within a Reynolds number less than approximately 500,000, for test models of varying shape. The design and manufacturing of a towing tank provides Arizona State University with laboratory equipment for experimental fluid mechanics. The design consists of a 3-meter-long, 0.5-meter-wide, and 0.8-meter-high cast acrylic tank with aluminum welded-frame supports. There is a pulling mechanism consisting of a belt drive and linear rail guide system that will be positioned on top of the tank. The pulling mechanism is currently in the prototype development stage. The prototype serves as a proof of concept for the final design, as data has been collected and analyzed using MATLAB, resolving the drag force of a submerged test model. This paper demonstrates the design process, prototype development, and construction of the towing tank. The original goal of this research was to answer questions about optimization of a swimmer’s technique by providing strong experimental results and deep analysis of the factors affecting performance. However, there were tasks along the way that shifted the focus from experimentation and analysis to design and manufacturing.
ContributorsAll, Isabella (Author) / Wells, Valana (Thesis director) / Pathikonda, Gokul (Committee member) / Hota , Piyush (Committee member) / Barrett, The Honors College (Contributor) / Mechanical and Aerospace Engineering Program (Contributor)
Created2022-05
Description
In this dissertation, two types of passive air freshener products from Henkel, the wick-based air freshener and gel-based air freshener, are studied for their wicking mechanisms and evaporation performances.The fibrous pad of the wick-based air freshener is a porous medium that absorbs fragrance by capillary force and releases the fragrance into the ambient air. To investigate the wicking process, a two-dimensional multiphase flow numerical model using COMSOL Multiphysics is built. Saturation and liquid pressure inside the pad are solved. Comparison between the simulation results and experiments shows that evaporation occurs simultaneously with the wicking process. The evaporation performance on the surface of the wicking pad is analyzed based on the kinetic theory, from which the mass flow rate of molecules passing the interface of each pore of the porous medium is obtained. A 3D model coupling the evaporation model and dynamic wicking on the evaporation pad is built to simulate the entire performance of the air freshener to the environment for a long period of time. Diffusion and natural convection effects are included in the simulation. The simulation results match well with the experiments for both the air fresheners placed in a chamber and in the absent of a chamber, the latter of which is subject to indoor airflow.
The gel-based air freshener can be constructed as a porous medium in which the solid network of particles spans the volume of the fragrance liquid. To predict the evaporation performance of the gel, two approaches are tested for gel samples in hemispheric shape. The first approach is the sessile drop model commonly used for the drying process of a pure liquid droplet. It can be used to estimate the weight loss rate and time duration of the evaporation. Another approach is to simulate the concentration profile outside the gel and estimate the evaporation rate from the surface of the gel using the kinetic theory. The evaporation area is updated based on the change of pore size. A 3D simulation using the same analysis is further applied to the cylindrical gel sample. The simulation results match the experimental data well.
ContributorsYuan, Jing (Author) / Chen, Kangping (Thesis advisor) / Herrmann, Marcus (Committee member) / Huang, Huei-Ping (Committee member) / Wang, Liping (Committee member) / Jiao, Yang (Committee member) / Arizona State University (Publisher)
Created2021
Description
Human exposure to extreme heat is becoming more prevalent due to increasing urbanization and changing climate. In many extreme heat conditions, thermal radiation (from solar to emitted by the surrounding) is a significant contributor to heating the body, among other modes of heat transfer. Therefore, accurately measuring radiative heat flux on a human body is becoming increasingly important for calculating human thermal comfort and heat safety in extreme conditions. Most often, radiant heat exchange between the human body and surroundings is quantified using mean radiant temperature, T_mrt. This value is commonly measured using globe or cylindrical radiometers. It is based on radiation absorbed by the surface of the radiometer, which can be calculated using a surface energy balance involving both convection and emitted radiation at steady state. This convection must be accounted for and is accomplished using a traditional heat transfer coefficient correlation with measured wind speed. However, the utilized correlations are based on wind tunnel measurements and do not account for any turbulence present in the air. The latter can even double the heat transfer coefficient, so not accounting for it can introduce major errors in T_mrt. This Thesis focuses on the development, and testing of a cost-effective heated cylinder to directly measure the convection heat transfer coefficient in field conditions, which can be used for accounting convection in measuring T_mrt using a cylindrical radiometer. An Aluminum cylinder of similar dimensions as that of a cylindrical radiometer was heated using strip heaters, and the surface temperature readings were recorded to estimate the convection heat transfer coefficient, h. Various tests were conducted to test this concept. It was observed that heated cylinders take significantly less time to reach a steady state and respond to velocity change quicker than existing regular-sized globe thermometers. It was also shown that, for accurate estimation of h, it is required to measure the outer surface temperature than the center temperature. Furthermore, the value calculated matches well in range with classic correlations that include velocity, showing proof of concept.
ContributorsGuddanti, Sai Susmitha (Author) / Rykaczewski, Konrad (Thesis advisor) / Vanos, Jennifer (Committee member) / Wang, Robert (Committee member) / Burke, Richard (Committee member) / Arizona State University (Publisher)
Created2023
Description
The microelectronics industry is actively focusing on advanced packaging technologies, notably on three-dimensional stacking of heterogeneous integrated (3D-HI) circuits for enhanced performance. Despite its computational performance benefits, this approach faces challenges in thermal management due to increased power density and heat generation. Conventional cooling methods struggle to address this issue effectively. This study investigates microfluidic intralayer cooling techniques using analytical correlation and computational fluid dynamics (CFD) principles to propose a method capable of managing thermal performance across varying load conditions. The proposed configuration achieved a dissipation of 40 W/cm2 with a volumetric flow rate of 200 mL/min, maintaining chip temperature at 315K. Additionally, extreme hotspot conditions generating 1kW/cm2, along with the presence of thermal resistance from redistribution layers (RDLs), are analyzed. This research aims to establish a model for understanding geometric property variations under different heat flux conditions in 3D heterogeneous integration of semiconductor packaging.
ContributorsGandhi, Rohit Mahavir (Author) / Wang, Robert Y (Thesis advisor) / Rykaczewski, Konrad (Committee member) / Kwon, Beomjin (Committee member) / Arizona State University (Publisher)
Created2024
Description
Gallium based room-temperature liquid metals (LMs) have special properties such as metal-like high thermal conductivity while in the liquid state. They are suitable for many potential applications, including thermal interface materials, soft robotics, stretchable electronics, and biomedicine. However, their high density, high surface tension, high reactivity with other metals, and rapid oxidation restrict their applicability. This dissertation introduces two new types of materials, LM foams, and LM emulsions, that address many of these issues. The formation mechanisms, thermophysical properties, and example applications of the LM foams and emulsions are investigated.LM foams can be prepared by shear mixing the bulk LM in air using an impeller. The surface oxide layer is sheared and internalized into the bulk LM as crumpled oxide flakes during this process. After a critical amount of oxide flakes is internalized, they start to stabilize air bubbles by encapsulating and oxide-bridging. This mechanism enables the fabrication of a LM foam with improved properties and better spreadability.
LM emulsions can be prepared by mixing the LM foam with a secondary liquid such as silicone oil (SO). By tuning a few factors such as viscosity of the secondary liquid, composition, and mixing duration, the thermophysical properties of the emulsion can be controlled. These emulsions have a lower density, better spreadability, and unlike the original LM and LM foam, they do not induce corrosion of other metals.
LM emulsions can form by two possible mechanisms, first by the secondary liquid replacing air features in the existing foam pores (replacement mechanism) and second by creating additional liquid features within the LM foam (addition mechanism). The latter mechanism requires significant oxide growth and therefore requires presence of oxygen in the environment. The dominant mechanism can therefore be distinguished by mixing LM foam with the SO in air and oxygen-free environments. Additionally, a comprehensive analysis of foam-to-emulsion density change, multiscale imaging and surface wettability confirm that addition mechanism dominates the emulsion formation. These results provide insight into fundamental processes underlying LM foams and emulsions, and they set up a foundation for preparing LM emulsions with a wide range of fluids and controllable properties.
ContributorsShah, Najam Ul Hassan (Author) / Rykaczewski, Konrad (Thesis advisor) / Wang, Robert (Thesis advisor) / Phelan, Patrick (Committee member) / Green, Matthew D. (Committee member) / Kwon, Beomjin (Committee member) / Arizona State University (Publisher)
Created2023
Description
The measurement of the radiation and convection that the human body experiences are important for ensuring safety in extreme heat conditions. The radiation from the surroundings on the human body is most often measured using globe or cylindrical radiometers. The large errors stemming from differences in internal and exterior temperatures and indirect estimation of convection can be resolved by simultaneously using three cylindrical radiometers (1 cm diameter, 9 cm height) with varying surface properties and internal heating. With three surface balances, the three unknowns (heat transfer coefficient, shortwave, and longwave radiation) can be solved for directly. As compared to integral radiation measurement technique, however, the bottom mounting using a wooden-dowel of the three-cylinder radiometers resulted in underestimated the total absorbed radiation. This first part of this thesis focuses on reducing the size of the three-cylinder radiometers and an alternative mounting that resolves the prior issues. In particular, the heat transfer coefficient in laminar wind tunnel with wind speed of 0.25 to 5 m/s is measured for six polished, heated cylinders with diameter of 1 cm and height of 1.5 to 9 cm mounted using a wooden dowel. For cylinders with height of 6 cm and above, the heat transfer coefficients are independent of the height and agree with the Hilpert correlation for infinitely long cylinder. Subsequently, a side-mounting for heated 6 cm tall cylinder with top and bottom metallic caps is developed and tested within the wind tunnel. The heat transfer coefficient is shown to be independent of the flow-side mounting and in agreement with the Hilpert correlation.
The second part of this thesis explores feasibility of employing the three-cylinder concept to measuring all air-flow parameters relevant to human convection including mean wind speed, turbulence intensity and length scale. Heated cylinders with same surface properties but varying diameters are fabricated. Uniformity of their exterior temperature, which is fundamental to the three-cylinder anemometer concept, is tested during operation using infrared camera. To provide a lab-based method to measure convection from the cylinders in turbulent flow, several designs of turbulence-generating fractal grids are laser-cut and introduced into the wind tunnel.
ContributorsGupta, Mahima (Author) / Rykaczewski, Konrad (Thesis advisor) / Pathikonda, Gokul (Thesis advisor) / Middel, Ariane (Committee member) / Arizona State University (Publisher)
Created2024
Description
In these times of increasing industrialization, there arises a need for effective and energy efficient heat transfer/heat exchange devices. The focus nowadays is on identifying various methods and techniques which can aid the process of developing energy efficient devices. One of the most common heat transfer devices is a heat exchanger. Heat exchangers are an essential commodity to any industry and their efficiency can play an important role in making industries energy efficient and reduce the energy losses in the devices, in turn decreasing energy inputs to run the industry.
One of the ways in which we can improve the efficiency of heat exchangers is by applying ultrasonic energy to a heat exchanger. This research explores the possibility of introducing the external input of ultrasonic energy to increase the efficiency of the heat exchanger. This increase in efficiency can be estimated by calculating the parameters important for the characterization of a heat exchanger, which are effectiveness (ε) and overall heat transfer coefficient (U). These parameters are calculated for both the non-ultrasound and ultrasound conditions in the heat exchanger.
This a preliminary study of ultrasound and its effect on a conventional shell-and-coil heat exchanger. From the data obtained it can be inferred that the increase in effectiveness and overall heat transfer coefficient upon the application of ultrasound is 1% and 6.22% respectively.
One of the ways in which we can improve the efficiency of heat exchangers is by applying ultrasonic energy to a heat exchanger. This research explores the possibility of introducing the external input of ultrasonic energy to increase the efficiency of the heat exchanger. This increase in efficiency can be estimated by calculating the parameters important for the characterization of a heat exchanger, which are effectiveness (ε) and overall heat transfer coefficient (U). These parameters are calculated for both the non-ultrasound and ultrasound conditions in the heat exchanger.
This a preliminary study of ultrasound and its effect on a conventional shell-and-coil heat exchanger. From the data obtained it can be inferred that the increase in effectiveness and overall heat transfer coefficient upon the application of ultrasound is 1% and 6.22% respectively.
ContributorsAnnam, Roshan Sameer (Author) / Phelan, Patrick (Thesis advisor) / Rykaczewski, Konrad (Committee member) / Milcarek, Ryan (Committee member) / Arizona State University (Publisher)
Created2019
Description
Additive manufacturing (AM) describes an array of methods used to create a 3D object layer by layer. The increasing popularity of AM in the past decade has been due to its demonstrated potential to increase design flexibility, produce rapid prototypes, and decrease material waste. Temporary supports are an inconvenient necessity in many metal AM parts. These sacrificial structures are used to fabricate large overhangs, anchor the part to the build substrate, and provide a heat pathway to avoid warping. Polymers AM has addressed this issue by using support material that is soluble in an electrolyte that the base material is not. In contrast, metals AM has traditionally approached support removal using time consuming, costly methods such as electrical discharge machining or a dremel.
This work introduces dissolvable supports to single- and multi-material metals AM. The multi-material approach uses material choice to design a functionally graded material where corrosion is the functionality being varied. The single-material approach is the primary focus of this thesis, leveraging already common post-print heat treatments to locally alter the microstructure near the surface. By including a sensitizing agent in the ageing heat treatment, carbon is diffused into the part decreasing the corrosion resistance to a depth equal to at least half the support thickness. In a properly chosen electrolyte, this layer is easily chemically, or electrochemically removed. Stainless steel 316 (SS316) and Inconel 718 are both investigated to study this process using two popular alloys. The microstructure evolution and corrosion properties are investigated for both. For SS316, the effect of applied electrochemical potential is investigated to describe the varying corrosion phenomena induced, and the effect of potential choice on resultant roughness. In summary, a new approach to remove supports from metal AM parts is introduced to decrease costs and further the field of metals AM by expanding the design space.
This work introduces dissolvable supports to single- and multi-material metals AM. The multi-material approach uses material choice to design a functionally graded material where corrosion is the functionality being varied. The single-material approach is the primary focus of this thesis, leveraging already common post-print heat treatments to locally alter the microstructure near the surface. By including a sensitizing agent in the ageing heat treatment, carbon is diffused into the part decreasing the corrosion resistance to a depth equal to at least half the support thickness. In a properly chosen electrolyte, this layer is easily chemically, or electrochemically removed. Stainless steel 316 (SS316) and Inconel 718 are both investigated to study this process using two popular alloys. The microstructure evolution and corrosion properties are investigated for both. For SS316, the effect of applied electrochemical potential is investigated to describe the varying corrosion phenomena induced, and the effect of potential choice on resultant roughness. In summary, a new approach to remove supports from metal AM parts is introduced to decrease costs and further the field of metals AM by expanding the design space.
ContributorsLefky, Christopher (Author) / Hildreth, Owen (Thesis advisor) / Chawla, Nikhilesh (Committee member) / Azeredo, Bruno (Committee member) / Rykaczewski, Konrad (Committee member) / Nian, Qiong (Committee member) / Arizona State University (Publisher)
Created2018