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- All Subjects: Mechanical Engineering
- Creators: Wang, Robert
Description
In nature, it is commonly observed that animals and birds perform movement-based thermoregulation activities to regulate their body temperatures. For example, flapping of elephant ears or plumage fluffing in birds. Taking inspiration from nature and to explore the possibilities of such heat transfer enhancements, augmentation of heat transfer rates induced by the vibration of solid and well as novel flexible pinned heatsinks were studied in this research project. Enhancement of natural convection has always been very important in improving the performance of the cooling mechanisms. In this research, flexible heatsinks were developed and they were characterized based on natural convection cooling with moderately vibrating conditions. The vibration of heated surfaces such as motor surfaces, condenser surfaces, robotic arms and exoskeletons led to the motivation of the development of heat sinks having flexible fins with an improved heat transfer capacity. The performance of an inflexible, solid copper pin fin heat sink was considered as the baseline, current industry standard for the thermal performance. It is expected to obtain maximum convective heat transfer at the resonance frequency of the flexible pin fins. Current experimental results with fixed input frequency and varying amplitudes indicate that the vibration provides a moderate improvement in convective heat transfer, however, the flexibility of fins had negligible effects.
ContributorsPrabhu, Saurabh (Author) / Rykaczewski, Konrad (Thesis advisor) / Phelan, Patrick (Committee member) / Wang, Robert (Committee member) / Arizona State University (Publisher)
Created2019
Description
Solar energy has become one of the most popular renewable energy in human’s life because of its abundance and environment friendliness. To achieve high solar energy conversion efficiency, it usually requires surfaces to absorb selectivity within one spectral range of interest and reflect strongly over the rest of the spectrum. An economic method is always desired to fabricate spectrally selective surfaces with improved energy conversion efficiency. Colloidal lithography is a recently emerged way of nanofabrication, which has advantages of low-cost and easy operation.
In this thesis, aluminum metasurface structures are proposed based on colloidal lithography method. High Frequency Structure Simulator is used to numerically study optical properties and design the aluminum metasurfaces with selective absorption. Simulation results show that proposed aluminum metasurface structure on aluminum oxide thin film and aluminum substrate has a major reflectance dip, whose wavelength is tunable within the near-infrared and visible spectrum with metasurface size. As the metasurface is opaque due to aluminum film, it indicates strong wavelength-selective optical absorption, which is due to the magnetic resonance between the top metasurface and bottom Al film within the aluminum oxide layer.
The proposed sample is fabricated based on colloidal lithography method. Monolayer polystyrene particles of 500 nm are successfully prepared and transferred onto silicon substrate. Scanning electron microscope is used to check the surface topography. Aluminum thin film with 20-nm or 50-nm thickness is then deposited on the sample. After monolayer particles are removed, optical properties of samples are measured by micro-scale optical reflectance and transmittance microscope. Measured and simulated reflectance of these samples do not have frequency selective properties and is not sensitive to defects. The next step is to fabricate the Al metasurface on Al_2 O_3 and Al films to experimentally demonstrate the selective absorption predicted from the numerical simulation.
In this thesis, aluminum metasurface structures are proposed based on colloidal lithography method. High Frequency Structure Simulator is used to numerically study optical properties and design the aluminum metasurfaces with selective absorption. Simulation results show that proposed aluminum metasurface structure on aluminum oxide thin film and aluminum substrate has a major reflectance dip, whose wavelength is tunable within the near-infrared and visible spectrum with metasurface size. As the metasurface is opaque due to aluminum film, it indicates strong wavelength-selective optical absorption, which is due to the magnetic resonance between the top metasurface and bottom Al film within the aluminum oxide layer.
The proposed sample is fabricated based on colloidal lithography method. Monolayer polystyrene particles of 500 nm are successfully prepared and transferred onto silicon substrate. Scanning electron microscope is used to check the surface topography. Aluminum thin film with 20-nm or 50-nm thickness is then deposited on the sample. After monolayer particles are removed, optical properties of samples are measured by micro-scale optical reflectance and transmittance microscope. Measured and simulated reflectance of these samples do not have frequency selective properties and is not sensitive to defects. The next step is to fabricate the Al metasurface on Al_2 O_3 and Al films to experimentally demonstrate the selective absorption predicted from the numerical simulation.
ContributorsGuan, Chuyun (Author) / Wang, Liping (Thesis advisor) / Azeredo, Bruno (Committee member) / Wang, Robert (Committee member) / Arizona State University (Publisher)
Created2019
Description
Additively Manufactured Thin-wall Inconel 718 specimens commonly find application in heat exchangers and Thermal Protection Systems (TPS) for space vehicles. The wall thicknesses in applications for these components typically range between 0.03-2.5mm. Laser Powder Bed Fusion (PBF) Fatigue standards assume thickness over 5mm and consider Hot Isostatic Pressing (HIP) as conventional heat treatment. This study aims at investigating the dependence of High Cycle Fatigue (HCF) behavior on wall thickness and Hot Isostatic Pressing (HIP) for as-built Additively Manufactured Thin Wall Inconel 718 alloys. To address this aim, high cycle fatigue tests were performed on specimens of seven different thicknesses (0.3mm,0.35mm, 0.5mm, 0.75mm, 1mm, 1.5mm, and 2mm) using a Servohydraulic FatigueTesting Machine. Only half of the specimen underwent HIP, creating data for bothHIP and No-HIP specimens. Upon analyzing the collected data, it was noticed that the specimens that underwent HIP had similar fatigue behavior to that of sheet metal specimens. In addition, it was also noticed that the presence of Porosity in No-HIP specimens makes them more sensitive to changes in stress. A clear decrease in fatigue strength with the decrease in thickness was observed for all specimens.
ContributorsSaxena, Anushree (Author) / Bhate, Dhruv (Thesis advisor) / Liu, Yongming (Committee member) / Kwon, Beomjin (Committee member) / Arizona State University (Publisher)
Created2021
Description
Laser powder bed fusion (LPBF) additive manufacturing (AM) has received widespread attention due to its ability to produce parts with complicated design and better surface finish compared to other additive techniques. LPBF uses a laser heat source to melt layers of powder particles and manufactures a part based on the CAD design. This process can benefit significantly through computational modeling. The objective of this thesis was to understand the thermal transport, and fluid flow phenomena of the process, and to optimize the main process parameters such as laser power and scan speed through a combination of computational, experimental, and statistical analysis. A multi-physics model was built using to model temperature profile, bead geometry and elemental evaporation in powder bed process using a non-gaussian interaction between laser heat source and metallic powder. Owing to the scarcity of thermo-physical properties of metallic powders in literature, thermal conductivity, diffusivity, and heat capacity was experimentally tested up to a temperature of 1400 degrees C. The values were used in the computational model, which improved the results significantly. The computational work was also used to assess the impact of fluid flow around melt pool. Dimensional analysis was conducted to determine heat transport mode at various laser power/scan speed combinations. Convective heat flow proved to be the dominant form of heat transfer at higher energy input due to violent flow of the fluid around the molten region, which can also create keyhole effect. The last part of the thesis focused on gaining useful information about several features of the bead area such as contact angle, porosity, voids and melt pool that were obtained using several combinations of laser power and scan speed. These features were quantified using process learning, which was then used to conduct a full factorial design that allows to estimate the effect of the process parameters on the output features. Both single and multi-response analysis are applied to analyze the output response. It was observed that laser power has more influential effect on all the features. Multi response analysis showed 150 W laser power and 200 mm/s produced bead with best possible features.
ContributorsAhsan, Faiyaz (Author) / Ladani, Leila (Thesis advisor) / Razmi, Jafar (Committee member) / Kwon, Beomjin (Committee member) / Nian, Qiong (Committee member) / Zhuang, Houlong (Committee member) / Arizona State University (Publisher)
Created2021
Description
In convective heat transfer processes, heat transfer rate increases generally with a large fluid velocity, which leads to complex flow patterns. However, numerically analyzing the complex transport process and conjugated heat transfer requires extensive time and computing resources. Recently, data-driven approach has risen as an alternative method to solve physical problems in a computational efficient manner without necessitating the iterative computations of the governing physical equations. However, the research on data-driven approach for convective heat transfer is still in nascent stage. This study aims to introduce data-driven approaches for modeling heat and mass convection phenomena. As the first step, this research explores a deep learning approach for modeling the internal forced convection heat transfer problems. Conditional generative adversarial networks (cGAN) are trained to predict the solution based on a graphical input describing fluid channel geometries and initial flow conditions. A trained cGAN model rapidly approximates the flow temperature, Nusselt number (Nu) and friction factor (f) of a flow in a heated channel over Reynolds number (Re) ranging from 100 to 27750. The optimized cGAN model exhibited an accuracy up to 97.6% when predicting the local distributions of Nu and f. Next, this research introduces a deep learning based surrogate model for three-dimensional (3D) transient mixed convention in a horizontal channel with a heated bottom surface. Conditional generative adversarial networks (cGAN) are trained to approximate the temperature maps at arbitrary channel locations and time steps. The model is developed for a mixed convection occurring at the Re of 100, Rayleigh number of 3.9E6, and Richardson number of 88.8. The cGAN with the PatchGAN based classifier without the strided convolutions infers the temperature map with the best clarity and accuracy.
Finally, this study investigates how machine learning analyzes the mass transfer in 3D printed fluidic devices. Random forests algorithm is hired to classify the flow images taken from semi-transparent 3D printed tubes. Particularly, this work focuses on laminar-turbulent transition process occurring in a 3D wavy tube and a straight tube visualized by dye injection. The machine learning model automatically classifies experimentally obtained flow images with an accuracy > 0.95.
ContributorsKang, Munku (Author) / Kwon, Beomjin (Thesis advisor) / Phelan, Patrick (Committee member) / Ren, Yi (Committee member) / Rykaczewski, Konrad (Committee member) / Sohn, SungMin (Committee member) / Arizona State University (Publisher)
Created2022
Description
The thermal conductivity of cadmium sulfide (CdS) colloidal nanocrystals (NCs) and magic-sized clusters (MSCs) have been investigated in this work. It is well documented in the literature that the thermal conductivity of colloidal nanocrystal assemblies decreases as diameter decreases. However, the extrapolation of this size dependence does not apply to magic-sized clusters. Magic-sized clusters have an anomalously high thermal conductivity relative to the extrapolated size-dependence trend line for the colloidal nanocrystals. This anomalously high thermal conductivity could probably result from the monodispersity of magic-sized clusters. To support this conjecture, a method of deliberately eliminating the monodispersity of MSCs by mixing them with colloidal nanocrystals was performed. Experiment results showed that mixtures of nanocrystals and MSCs have a lower thermal conductivity that falls approximately on the extrapolated trendline for colloidal nanocrystal thermal conductivity as a function of size.
ContributorsSun, Ming-Hsien (Author) / Wang, Robert (Thesis advisor) / Rykaczewski, Konrad (Committee member) / Wang, Liping (Committee member) / Arizona State University (Publisher)
Created2022
Description
Dehumidifiers are ubiquitous and essential household appliances in many parts of the world. They are used extensively in tropical and sub-tropical environments to lower humidity in living spaces, where high ambient humidity can lead to numerous negative health effects from mild physical discomfort to more serious conditions such as mold build up in structures and dangerous illnesses in humans. Most common dehumidifiers are based on conventional mechanical refrigeration cycles, where the effects of condensation heat transfer play a critical role in their effectiveness. In these devices, humid ambient air flows over a cold evaporator, which lowers the temperature of the humid ambient air below its dew point temperature and therefore decreases its water content by causing liquid water condensation on the evaporator surface. The rate at which humidity can be extracted from the ambient air is governed in part by how quickly the evaporator can shed the condensed droplets. Recent advances in soft, stretchable, thermally enhanced (through the addition of liquid metals) silicone tubing offer the potential to use these stretchable tubes in place of conventional copper pipe for applications such as dehumidification. Copper is a common material choice for dehumidifier evaporator tubing owing to its ubiquity and its high thermal conductivity, but it has several thermal downsides. Specifically, copper tubes remain static and typically rely on gravity alone to remove water droplets when they reach a sufficient mass. Additionally, copper’s naturally hydrophilic surface promotes film-wise condensation, which is substantially less effective than dropwise condensation. In contrast to copper, thermally enhanced soft stretchable tubes have naturally hydrophobic surfaces that promote the more effective dropwise condensation mode and a soft surface that offers higher nucleation density. However, soft surfaces also increase droplet pinning, which inhibits their departure. This work experimentally explores the effects of periodic axial stretching and retraction of soft tubing internally cooled with water on droplet condensation dynamics on its exterior surface. Results are discussed in terms of overall system thermal performance and real-time condensation imaging. An overall null result is discovered, and recommendations for future experiments are made.
Contributorsnordstog, thomas (Author) / Rykaczewski, Konrad (Thesis advisor) / Wang, Robert (Committee member) / Devasenathipathy, Shankar (Committee member) / Arizona State University (Publisher)
Created2022
Description
This dissertation is focused on the rheology scaling of metal particle reinforced polymermatrix composite made of solid and nanoporous metal powders to enable their
continuous 3D printing at high (>60vol%) metal content. There remained a specific
knowledge gap on how to predict successful extrusion with densely packed metals by
utilizing their suspension melt rheological properties. In the first project, the scaling of
the dynamic viscosity of melt-extrudate filaments made of Polylactic acid (PLA) and
gas-atomized solid NiCu powders was studied as a function of the metal’s volumetric
packing and feedstock pre-mixing strategies and correlated to its extrudability
performance, which fitted well with the Krieger-Dougherty analytical model. 63.4
vol% Filaments were produced by employing solution-mixing strategy to reduce
sintered part porosity and shrinkage. After sintering, the linear shrinkage dropped by
76% compared to the physical mixing. By characterizing metal particle reinforced
polymer matrix composite feedstock via flow-sweep rheology, a distinct extension of
shear-thinning towards high shear rates (i.e. 100 s-1) was observed at high metal content
– a result that was attributed to the improved wall adhesion. In comparison, physically mixed filament failed to sustain more than 10s-1 shear rate proving that they were prone
to wall slippage at a higher shear rate, giving an insight into the onset of extrusion
jamming. In the second project, nanoporous copper made out of electroless chemical
dealloying was utilized as fillers, because of their unique physiochemical properties.
The role of capillary imbibition of polymers into metal nanopores was investigated to
understand their effect on density, zero-shear viscosity, and shear thinning. It was
observed that, although the polymeric fluid’s transient concentration regulates its
wettability, the polymer chain length ultimately dictates its melt rheology, which consequentially facilitates densification of pores during vacuum annealing. Finally, it
was demonstrated that higher imbibition into nanopores leads to extrusion failure due
to a combined effect of volumetric packing increase and nanoconfinement, providing a
deterministic materials design tool to enable continuous 3D printing. The outcome of
this study might be beneficial to integrate nanoporous metals into binder-based 3D
printing technology to fabricate interdigitated battery electrodes and multifunctional 3D
printed electronics.
ContributorsHasib, Amm (Author) / Azeredo, Bruno (Thesis advisor) / Song, Kenan (Thesis advisor) / Nian, Qiong (Committee member) / Kwon, Beomjin (Committee member) / Li, Xiangjia (Committee member) / Arizona State University (Publisher)
Created2022
Description
Ethylene is one of the most widely used organic compounds worldwide with ever increasing demand. Almost all the industries currently producing ethylene globally use the method of steam cracking, which, though highly selective and cost effective, is energy intensive along with having a high carbon footprint. This study aims to analyze micro-scale partial oxidation of propane as a novel approach towards ethylene generation which is simpler, less energy consuming, operates at lower temperatures and causes minimum CO2 emission. The experimental study endeavors to maximize the ethylene production by investigating the effect of variables such as temperature, flow rate, equivalence ratio and reactor diameter. The micro-scale partial oxidation of propane is studied inside quartz tube reactors of 1 mm and 3 mm diameter at a temperature range of 800 to 900 oC, at varying flow rates of 10 to 100 sccm and equivalence ratios of 1 to 6. The study reveals ethylene yield has a strong dependence on all the above factors. However, the factors are not completely independent of each other. Adjusting certain factors and levels results in greater ethylene yields as high as 10%, but propane to ethylene conversion efficiency is approximately constant for most conditions. Low CO2 concentrations are also recorded for most of the factor and level combinations, indicating the potential to achieve lower CO2 yields compared to conventional approaches. The investigation indicates promise for application in the field of ethylene generation.
ContributorsMAHALKAR, PAWAN MUKUND (Author) / Milcarek, Ryan (Thesis advisor) / Kwon, Beomjin (Committee member) / Phelan, Patrick (Committee member) / Arizona State University (Publisher)
Created2023
Description
Energy storage technologies are essential to overcome the temporal variability in renewable energy. The primary aim of this thesis is to develop reactor solutions to better analyze the potential of thermochemical energy storage (TCES) using non-stoichiometric metal oxides, for the multi-day energy storage application. A TCES system consists of a reduction reactor and an insulated MOx storage bin. The reduction reactor heats (to ~ 1100 °C) and partially reduces the MOx, thereby adding sensible and chemical energy (i.e., charging it) under reduced pO2 environments (~10 Pa). Inert gas removes the oxygen generated during reduction. The storage bin holds the hot and partially reduced MOx (typically particles) until it is used in an energy recovery device (i.e., discharge). Irrespective of the reactor heat source (here electrical), or the particle-inert gas flows (here countercurrent), the thermal reduction temperature and inert gas (here N2) flow minimize when the process approaches reversibility, i.e., operates near equilibrium. This study specifically focuses on developing a reduction reactor based on the theoretical considerations for approaching reversibility along the reaction path. The proposed Zigzag flow reactor (ZFR) is capable of thermally reducing CAM28 particles at temperatures ~ 1000 °C under an O2 partial pressure ~ 10 Pa. The associated analytical and numerical models analyze the reaction equilibrium under a real (discrete) reaction path and the mass transfer kinetic conditions necessary to approach equilibrium. The discrete equilibrium model minimizes the exergy destroyed in a practical reactor and identifies methods of maximizing the energy storage density () and the exergetic efficiency. The mass transfer model analyzes the O2 N2 concentration boundary layers to recommend sizing considerations to maximize the reactor power density. Two functional ZFR prototypes, the -ZFR and the -ZFR, establish the proof of concept and achieved a reduction extent, Δδ = 0.071 with CAM28 at T~950 °C and pO2 = 10 Pa, 7x higher than a previous attempt in the literature. The -ZFR consistently achieved > 100 Wh/kg during >10 h. runtime and the -ZFR displayed an improved = 130 Wh/kg during >5 h. operation with CAM28. A techno-economic model of a grid-scale ZFR with an associated storage bin analyzes the cost of scaling the ZFR for grid energy storage requirements. The scaled ZFR capital costs contribute < 1% to the levelized cost of thermochemical energy storage, which ranges from 5-20 ¢/kWh depending on the storage temperature and storage duration.
ContributorsGhotkar, Rhushikesh (Author) / Milcarek, Ryan (Thesis advisor) / Ermanoski, Ivan (Committee member) / Phelan, Patrick (Committee member) / Wang, Liping (Committee member) / Wang, Robert (Committee member) / Arizona State University (Publisher)
Created2023