High Injection Velocity Research Articles

Experimental and numerical study of characteristic parameters of Taylor bubble in vertical pipe under short-time gas injection

Purpose This study aims to investigate the formation and characteristics of Taylor bubbles resulting from short-time gas injection in liquid-conveying pipelines. Understanding these characteristics is crucial for optimizing pipeline efficiency and enhancing production safety. Design/methodology/approach The authors conducted short-time gas injection experiments in a vertical rectangular pipe, focusing on Taylor bubble formation time and stable length. Computational fluid dynamics simulations using large eddy simulation and volume of fluid models were used to complement the experiments. Findings Results reveal that the stable length of Taylor bubbles is significantly influenced by gas injection velocity and duration. Specifically, high injection velocity and duration lead to increased bubble aggregation and recirculation region capture, extending the stable length. Additionally, a higher injection velocity accelerates reaching the critical local gas volume fraction, thereby reducing formation time. The developed fitting formulas for stable length and formation time show good agreement with experimental data, with average errors of 6.5% and 7.39%, respectively. The predicted values of the formulas in glycerol-water and ethanol solutions are also in good agreement with the simulation results. Originality/value This research provides new insights into Taylor bubble dynamics under short-time gas injection, offering predictive formulas for bubble formation time and stable length. These findings are valuable for optimizing industrial pipeline designs and mitigating potential safety issues.

Pore-scale study of [formula omitted] desublimation in a contact liquid

Cryogenic carbon capture (CCC) designed to operate in a contact liquid is an innovative technology for capturing CO2 from industrial flue gases, helping mitigate climate change. Understanding CO2 desublimation properties in a contact liquid is crucial to optimizing CCC, but is challenging due to the complex physics involved. In this work, a multiphysics lattice Boltzmann (LB) model is developed to investigate CO2 desublimation in a contact liquid for various operating conditions, with the multiple and fully-coupled physics being incorporated (i.e., two-phase flow, heat transfer across three phases, CO2 transport between the gas and liquid, homogeneous and heterogeneous desublimation of CO2, and solid CO2 generation). The CO2 desublimation process in a contact liquid is well reproduced. Moreover, parametric studies and quantitative analyses are set out to identify optimal conditions for CCC. The decreasing liquid temperature (Tl) and flue gas temperature (T0) are found to accelerate the CO2 desublimation rate and enhance the CO2 capture velocity (vc). However, excessively low Tl and T0 values should be avoided. These conditions increase the energy consumption of cooling while only marginally improving vc, due to the limited CO2 supply. The CCC system performs effectively when purifying flue gases with high CO2 content (Y0). This is because the large Y0 accelerates the CO2 desublimation rate and enhances the overall CO2 capture efficiency. A high gas injection velocity (or Pe) is beneficial for amplifying vc by increasing the gas–liquid interfaces and enhancing the CO2 supply. Nevertheless, too high a Pe should be avoided, as it hinders the transport of CO2 to the liquid or solid CO2 surfaces, ultimately restricting the amount of CO2 available for desublimation and inhibiting the enhancement of vc. This study develops a viable LB model to investigate CO2 desublimation in a contact liquid for varying conditions, which advances the knowledge base of CCC and facilitates its industrial applications.

Intrinsic performance limits of extremely scaled field-effect transistors based on MX2 (M = {Zr, Hf}, X = {S, Se}) nanoribbons

We investigate the MX2 (M = {Hf, Zr}, X = {S, Se}) transition metal dichalcogenides patterned into armchair (AC) and zigzag (ZZ) nanoribbons (NRs) as potential channel materials in future logic field-effect devices. Ab initio quantum transport simulations are employed to assess the electronic, transport, and ballistic field-effect transistor (FET) properties of devices with such quasi-one-dimensional channels. We report a non-monotonic scaling behavior of MX2NR properties due to strong quantum confinement effects, which is reflected in a strong dependence of the ON-state current (ION) of MX2NR FETs on the nanoribbon configuration. The ∼2 nm-wide HfSe2 and ZrSe2 AC-PFETs have the highest ION of up to 2.6 mA/μm at 10 nA/μm OFF-state current. Surprisingly, MX2NR ZZ-NFETs exhibit a current increase of up to 70% when channel width is scaled down, with ION reaching 2.2 mA/μm in ∼2 nm-wide devices. The high ON-state performance is a direct consequence of high carrier injection velocity, which is explained by analyzing the band structure, transmission, and density of states. We demonstrate that nanostructured MX2 materials can be promising candidates for future logic transistors based on multi-nanowire architectures.

Numerical Simulation of Geothermal Energy Development at Mount Meager and Its Impact on In Situ Thermal Stress

The Meager Mountain Geothermal Project stands as one of the pioneering geothermal energy initiatives in its early stages of resource development. Despite its abundant geothermal heat resources, no prior studies have systematically evaluated the potential of implementing coaxial borehole heat exchangers on site. This study addresses this research gap by presenting a comprehensive heat transfer model for an underground closed-loop geothermal system utilizing a single coaxial well. Finite element analysis incorporated fluid and solid heat transfer, as well as solid mechanics. The results obtained facilitated the construction of the temperature and thermal stress profiles induced by the cooling effects resulting from years of heat extraction. After 25 years of operation, the outlet temperature has reached approximately 74 °C, and the maximum radial tensile thermal stress amounts to ~47 MPa. Furthermore, the analysis demonstrates that higher fluid velocities contribute to more perturbed temperature and stress distributions. The study attained maximum thermal and electric power outputs of 208 kW and 17 kW, respectively. This research also underscores the significant impact of geothermal gradient and well length on BHE design, with longer wells yielding more power, especially at higher injection velocities.

Blind zones in radiating dispersion at high Péclet number driven by non-Newtonian fluids in porous media

A wide range of environmental, energy, medical and biological processes rely on dispersive transport through complex media. Yet, because of the stagnant and opaque nature of the microscopic system, the role of disordered flow and structure in the dispersive transport of solutes remains poorly understood. Here, we use a circular porous microfluidic system to investigate the radial dispersion in porous media driven by non-Newtonian fluids with strong advection rate (or at high Péclet number) and low-to-moderate Reynolds numbers. We observe for the first time the presence of diffusion ‘blind zones’ in the microstructure for high solution injection velocities. More specifically, an in-depth analysis uncovers that the circumferential flow frame, coformed by obstacles and vortices especially the ‘twin-vortex’ with same rotation direction, is responsible for the diffusion ‘blind zones’ and transport heterogeneity. The vortices are induced by the coupling of microfluidics and porous structures, and correlated to inertial flow-induced instabilities. The trade-off between diffusion efficiency and quality/completeness with respect to the high Péclet number (or high inlet velocity) serves to enhance our comprehension of intricate fluid dynamics and affords a set of principles to aid a diverse range of practical implementations.

Small Molecule Additives to Suppress Bundling in Dimensional‐Limited Self‐Alignment Method for High‐Density Aligned Carbon Nanotube Array

AbstractSemiconducting single‐walled carbon nanotube (CNT) is a promising candidate as a channel material for advanced logic transistors, attributed to the ultra‐thin 1‐nm cylindrical geometry, high mobility, and high carrier injection velocity. However, the presence of undesired CNT bundles in the CNT arrays for wafer‐scale device fabrication, even when utilizing the state‐of‐the‐art dimension‐limited self‐alignment (DLSA) method, poses challenges. These CNT bundles degrade the transistor gate's efficiency in controlling the flow of charge carriers in the CNT channel, leading to pronounced device‐to‐device variability. Here, a novel method is introduced to alleviate bundling in CNT arrays assembled via DLSA, by involving small molecule additive to screen the attractive van der Waals force between neighboring CNTs during the DLSA process, resulting in over 50% reduction in CNT bundling. Furthermore, a pioneering methodology for quantifying CNT bundles is presented and employed experimentally to assess bundles in dense CNT arrays assembled by DLSA using transmission electron microscopy. Both experimental data and molecular dynamics simulation reveal that CNT bundling originates from van der Waals attraction between CNTs, and the disturbed liquid‐liquid interface by accumulating excess polar molecules. These findings illuminate new pathways for realizing dense, bundle‐free CNT arrays.

Optimizing of particle accelerated rotor parameters using the discrete element method.

The acceleration capability of a centrifugal jet rotor plays a crucial role in achieving a high injection velocity of powder particles in the centrifugal impact moulding process. In this regard, the focus of this article is on optimization of the runner shape. To this end, the lengths of the first and second acceleration sections (L1 and L2), and the angles between the first and second acceleration sections and between the second and third sections (α1 and α2) are considered as the rotor parameters. Simulations were conducted using multiple discrete elements to explore the influence of multiple input parameters on the response value, and a regression model was established between the parameters and the particle injection rate. The experimental results show that the selected parameters significantly affect the rate of particle injection, and the interactions between the parameters L1 and L2, and between L2 and α2 have the largest effects. The results reveal that applying the optimized parameters improves the particle injection speed by 7.85% when compared to the pre-optimization model. This improvement in the rotor acceleration provides the basis for improving the efficiency of centrifugal impact moulding of metal powders.

Effect of injection molding conditions on the properties of polyamide 6/calcium carbonate nanocomposite

AbstractThe application range of polyamide 6 in lightweight part applications can be significantly increased by using appropriate processing parameters and by incorporating additives. Therefore, specimens were manufactured at varying mold temperatures and injection velocities to study the effect of injection molding parameters on the properties of polyamide 6 and its nanocomposite with nano‐calcium carbonate. Mechanical properties, degree of crystallinity, density, heat deflection temperature, and melt flow index were measured to assess the effect of injection molding conditions on material properties. Mold temperature was the process factor that most affected polyamide 6 and polyamide 6/nano‐calcium carbonate properties. Increasing this parameter increased density, impact strength, flexural strength, flexural modulus, and heat deflection temperature. The nanocomposite's degree of crystallinity, tensile modulus, and melt flow index also increased. High injection velocity reduced only the impact strength of the nanocomposite. The findings indicate that by modifying injection parameters, it is possible to improve mechanical properties and processing efficiency of polyamide 6 and its nanocomposites, bringing them closer to their maximum potential. Incorporating the nanofiller increased almost all properties except for impact strength and elongation at break. Nano‐calcium carbonate provided considerable advantages to polyamide 6 mechanical performance and processability while increasing sample weight by only 1.5%.

Stability and Migration Characteristics of SDS and SiO2 Colloidal Gas Aphron and Its Removal Efficiency for Nitrobenzene-Contaminated Aquifers

The instability of colloidal gas aphrons (CGAs) in aquifers is one of the major obstacles influencing the remediation efficiency of CGAs-flushing. In this study, hydrophobic nano-SiO2 (HN-SiO2) was utilized to enhance the stability of CGAs. The batch experiments were carried out to investigate the effect of hydrogeochemical conditions on the stability of HN-SiO2 stabilized CGAs in aquifers, such as ions, pH, and nitrobenzene (NB); 2-D tank experiments designed with various injection velocities and medium particle sizes were conducted to determine the factors influencing the migration of CGAs in the aquifer; and 1-D column experiments were established to evaluate the remediation efficiency of HN-SiO2 stabilized CGAs flushing for NB removal. The results indicated that HN-SiO2 had a favorable effect on the stability of CGAs, which enhanced the half-life of CGAs from 328 to 1,050 s. HN-SiO2 particles formed a shell film on the gas-liquid interface of CGAs to slow down the gas escape and drainage velocity. The stability of CGAs decreased while pH<6 or pH>8, whereas this was enhanced with the addition of 0.1 wt.% NaCl. The 2-D tank experiments demonstrated that the HN-SiO2 stabilized CGAs had better stability when they flowed in aquifers compared to sodium dodecyl sulfate (SDS) CGAs. The fine medium and high injection velocity facilitated CGAs forming the larger radius remediation area. The injection pressure was inversely proportional to the medium grain sizes, whereas directly proportional to the injection velocities. In addition, column experiments demonstrated the remediation efficiency of HN-SiO2 stabilized CGAs (81.7%) flushing for NB removal was higher than that of SDS CGAs (61.4%) flushing. Therefore, in comparison with SDS CGAs, HN-SiO2 stabilized CGAs were more efficient reagents for NB removal. CGAs-flushing technique using HN-SiO2 stabilized CGAs is feasible to remedy the contaminated aquifers.

Design and platform testing of the compact torus central fueling device for the EAST tokamak

Compact torus (CT) injection is a highly promising technique for the central fueling of future reactor-grade fusion devices since it features extremely high injection velocity and relatively high plasma mass. Recently, a CT injector for the EAST tokamak, EAST-CTI, was developed and platform-tested. In the first round of experiments conducted with low parameter settings, the maximum velocity and mass of the CT plasma were 150 km·s−1 and 90 μg, respectively. However, the parameters obtained by EAST-CTI were still very low and were far from the requirements of a device such as EAST that has a strong magnetic field. In future, we plan to solve the spark problem that EAST-CTI currently encounters (that mainly hinders the further development of experiments) through engineering methods, and use greater power to obtain a more stable and suitable CT plasma for EAST.

Vertical GeSn nanowire MOSFETs for CMOS beyond silicon

The continued downscaling of silicon CMOS technology presents challenges for achieving the required low power consumption. While high mobility channel materials hold promise for improved device performance at low power levels, a material system which enables both high mobility n-FETs and p-FETs, that is compatible with Si technology and can be readily integrated into existing fabrication lines is required. Here, we present high performance, vertical nanowire gate-all-around FETs based on the GeSn-material system grown on Si. While the p-FET transconductance is increased to 850 µS/µm by exploiting the small band gap of GeSn as source yielding high injection velocities, the mobility in n-FETs is increased 2.5-fold compared to a Ge reference device, by using GeSn as channel material. The potential of the material system for a future beyond Si CMOS logic and quantum computing applications is demonstrated via a GeSn inverter and steep switching at cryogenic temperatures, respectively.

Transport simulations of pre-thermal quench shattered pellet injection in ITER: code verification and assessment of key trends

The material assimilation of the shattered pellet injection (SPI) in the pre-thermal quench phase in ITER is studied numerically by means of one-dimensional (1D) transport simulations. Such a simplified 1D approach is useful to perform extensive and systematic studies of key engineering parameters to optimize the ITER Disruption Mitigation System. The simulation results are compared with two-dimensional (2D) axisymmetric simulations by the nonlinear magnetohydrodynamic code JOREK for 5 neon/95 hydrogen SPI in the 15 MA hydrogen L-mode discharge to clarify the characteristics of SPI assimilation that can be analyzed within the range of the 1D model. Reasonable agreement between the 1D SPI simulation by the INDEX code and the 2D simulations by the JOREK code is found for total ablation rates, the radiation power, and the density and temperature profile evolution. The key process that was studied with the transport code is the onset of the radiative cold front that destabilizes the plasma current profiles. The injection parameters for the neon mixed hydrogen SPI are widely scanned to identify the timescale for the radiative cold front to form. Depending on the relative velocity of the cold front and the SPI fragments, the plasma cooling process can differ significantly. SPI with high injection velocities and large shard sizes results even in an inside-out plasma cooling that leads to hollow temperature profiles in the simulations reported here.

Displacement Characteristics and Produced Oil Properties in Steam Flood Heavy Oil Process

Thermal recovery is one of the most effective techniques for viscous oil production, which has been widely used in the heavy oilfield development. The mechanisms and percolation characteristics of thermal recovery have attracted a lot of attention. However, the displacement characteristics and produced oil properties in the steam flood heavy oil process are rarely addressed. In this paper, steam flooding experiments with two heavy oil viscosities under the temperatures from 120 to 200 °C and velocities from 1 to 3 mL/min were carried out to examine the oil displacement efficiency and the produced oil properties. The results show that the majority of the oil is produced in the low water cut stage. Temperature increment is helpful for prolonging the water breakthrough time. The high injection velocity of steam contributes to a high recovery factor, even if it enters into the high water cut stage. The rheology of the produced oils severely changes because the SARA composition changes, and emulsification occurs during the steam flooding heavy oil process. With the increasing steam temperature, the relative content of resins in the produced oils decreases, and asphaltenes increase. With the increase in the injection volume and the injection velocity of steam, the content of resins and asphaltenes increases. This leads to an increment in the produced oil viscosities. The effect of injection velocity on the rheology properties of the produced oils increases with temperature increment. The finding of this work will provide the technical support for heavy oilfields development.

The effect of gas injection velocity and pore morphology on displacement mechanisms in porous media based on CFD approach

Because of the unique advantages such as easy miscibility, high temperature resistance and so on, hydrocarbon gas flooding has proved to be a promising technology for enhanced oil recovery in deep reservoirs. In order to reveal the potential mechanism of miscibility and displacement of crude oil and hydrocarbon gas, an innovative two-dimensional physical field model is constructed by coupling Navier-Stokes equations and mass transfer equation. Accordingly, the effect of gas injection velocity and pore morphology on fluid transport and miscibility properties is investigated based on computational fluid dynamics approach. The simulation results demonstrated that the residual oil (RO) content is lower at low gas injection velocity than that at high gas injection velocity due to the better miscibility of fluids. For pore morphology, the RO content increases with increasing pore throat ratio and pore throat angle, which are not related to the gas injection velocity. The blocked pore structure has a negative effect on hydrocarbon gas flooding, resulting in the higher RO content. In addition, the influence of the pore throat length on the RO content is related to the gas injection velocity, which means the RO content increases at low gas injection velocity and decreases at high gas injection velocity with increasing pore throat length.

A Simulation Study on the Transient Behavior of a Gasoline Direct Injection Engine under Cold Start Conditions

&lt;div class="section abstract"&gt;&lt;div class="htmlview paragraph"&gt;The cold start process is critical to control the emissions in a gasoline direct injection (GDI) engine. However, the optimization is very challenging due to the transient behavior of the engine cold start. A series of engine simulations using CONVERGE CFD™ were carried out to show the detailed process in the very first firing event of a cold start. The engine operating parameters used in the simulations, such as the transient engine speed and the fuel rail pressure (FRP), came from companion experiments. The cylinder pressure traces from the simulations were compared with experiments to help validate the simulation model. The effects of variation of the transient parameters on in-cylinder mixture distribution and combustion are presented, including the effects of the rapidly changing engine speed, the slowly vaporized fuel due to the cold walls, and the low FRP during the first firing cycle of a 4-cylinder engine. Comparison was also made with non-transient steady state operation. It was shown that the injection-induced tumble ratio in the cylinder varied for different engine speed cases, resulting in a better fuel distribution in the low engine speed case. A relatively high turbulence level during the combustion process was seen in the transient engine speed case that led to strengthened combustion. The fuel tracking from the simulation indicated that about 30% of the fuel remained unreacted at a very late crank angle, in which 8% was in the gas phase and 22% in the liquid phase as wall films. As the FRP increased, the fuel droplets became smaller, and more fuel vaporized before hitting the piston. But the splash and rebound fuel fraction off the piston bowl was even less, resulting in a lower overall gas-phase equivalence ratio in the first firing event for the high FRP case. On the other hand, the fuel distribution was more homogeneous under the high FRP condition due to the high injection velocities. There should be an optimal FRP value, but it was difficult to discern since the peak pressures in different FRP cases were similar and turbulence levels varied in a non-monotonic way, as well, which would lead to cycle-to-cycle variations in the real engine.&lt;/div&gt;&lt;/div&gt;

Computational comparison of the conventional diesel and hydrogen direct-injection compression-ignition combustion engines

Most research and development on hydrogen (H2) internal combustion engines focus on premixed-charge spark ignition (SI) or diesel-hydrogen dual-fuel technologies. Premixed charge limits the engine efficiency, power density, and safety, while diesel injections give rise to CO2 and particulate emissions. This paper demonstrates a non-premixed compression-ignition (CI) neat H2 engine concept that uses H2 pilots for ignition. It compares the CI H2 engine to an equivalent diesel engine to draw fundamental insights about the mixing and combustion processes. The Converge computational fluid dynamics solver is used for all simulations. The results show that the brake thermal efficiency of the CI H2 engine is comparable or higher than diesel, and the molar expansion with H2 injections at TDC constitutes 5–10 % of the total useful work. Fuel-air mixing in the free-jet phase of combustion is substantially higher with H2 due to hydrogen’s gaseous state, low density, high injection velocity, and transient vortices, which contribute to the 3 times higher air entrainment into the quasi-steady-state jet regions. However, the H2 jet momentum is up to 4 times lower than for diesel, which leads to not only ineffective momentum-driven global mixing but also reduced heat transfer losses with H2. The short H2 flame quenching distance may also be inconsequential for heat transfer in CI engines. Finally, this research enables future improvements in CI H2 engine efficiency by hypothesizing a new optimization path, which maximizes the free-jet phase of combustion, hence is totally different from that for conventional diesel engines.

Transition from no-ELM response to pellet ELM triggering during pedestal build-up—insights from extended MHD simulations

Pellet edge localized mode (ELM) triggering is a well-established scheme for decreasing the time between two successive ELM crashes below its natural value. Reliable ELM pacing has been demonstrated experimentally in several devices, increasing the ELM frequency considerably. However, it was also shown that the frequency cannot be increased arbitrarily due to a so-called lag-time. During this time, after a preceding natural or triggered ELM crash, neither a natural ELM crash occurs nor is it possible to trigger an ELM crash by pellet injection. For this article, pellet ELM triggering simulations are advanced beyond previous studies in two ways. Firstly, realistic E × B and diamagnetic background flows are included. And secondly, the pellet is injected at different stages of the pedestal build-up. This allows us to recover the lag time for the first time in simulations and investigate it in detail. A series of nonlinear extended MHD simulations is performed to investigate the plasma dynamics resulting from an injection at different time points during the pedestal build-up. The experimentally observed lag-time is qualitatively reproduced. In particular, a sharp transition is observed between the regime where no ELMs can be triggered and the regime where pellet injection causes an ELM crash. Via variations of pellet parameters and injection time, the two regimes are studied and compared in detail, revealing pronounced differences in the nonlinear dynamics. The toroidal mode spectrum is significantly broader when an ELM crash is triggered, enhancing the stochasticity and therefore also the losses of thermal energy along magnetic field lines. In the heat fluxes to the divertor targets, pronounced toroidal asymmetries are observed. In the case of high injection velocities leading to deep penetration, the excitation of core modes like the 2/1 neoclassical tearing mode is also observed.

Strained Si/Si1−yCy superlattice based quasi-read avalanche transit-time devices for terahertz ultrafast switches

Effects of selective carbon (C) incorporation in silicon (Si) quasi-read-avalanche-transit-time (QRATT) devices are studied through indigenously developed non-linear Strain-corrected-mixed-quantum-tunneling-drift–diffusion-model (SMQTDDM). A superlattice with alternate thin films of strained-Si and comparatively thick layers of Si0.99C0.01 stressors constitutes the active region. Out-of-plane mobility enhancement occurs due to the in-plane biaxial strain at Si/Si0.99C0.01 interfaces. Band offset between Si/Si0.99C0.01results in high injection velocity. Combined effect of strain-engineering and band offset amounts to the application of periodic accelerating pulse along the active region. This subsequently reduces carrier transit-time and results in THz oscillation in Si-ATT-diode. Remarkable RF performance (RF-power ~ $$23.2\times {10}^{8}$$ W/m2 at 0.73 THz) of exotic Si-QRATT-devices is reported for the first time. The simulation incorporates quantum-effects, process-induced-strain, parasitic-resistance, thermal-model and inter-sub-band-tunneling in the dispersion relation of the multiple-quantum-wells through a combined solution of Schrodinger–Poisson equations. The theoretical analysis is verified with experimental observations for in-house-fabricated Si-ATT-diodes. QRATT-device-based THz series-shunt switches are further explored.

Pore-Scale Simulations of CO2/Oil Flow Behavior in Heterogeneous Porous Media under Various Conditions

Miscible and near-miscible flooding are used to improve the performance of carbon-dioxide-enhanced oil recovery in heterogeneous porous media. However, knowledge of the effects of heterogeneous pore structure on CO2/oil flow behavior under these two flooding conditions is insufficient. In this study, we construct pore-scale CO2/oil flooding models for various flooding methods and comparatively analyze CO2/oil flow behavior and oil recovery efficiency in heterogeneous porous media. The simulation results indicate that compared to immiscible flooding, near-miscible flooding can increase the CO2 sweep area to some extent, but it is still inefficient to displace oil in small pore throats. For miscible flooding, although CO2 still preferentially displaces oil through big throats, it may subsequently invade small pore throats. In order to substantially increase oil recovery efficiency, miscible flooding is the priority choice; however, the increase of CO2 diffusivity has little effect on oil recovery enhancement. For immiscible and near-miscible flooding, CO2 injection velocity needs to be optimized. High CO2 injection velocity can speed up the oil recovery process while maintaining equivalent oil recovery efficiency for immiscible flooding, and low CO2 injection velocity may be beneficial to further enhancing oil recovery efficiency under near-miscible conditions.

Experimental investigation and numerical simulation of the microinjection molding process through an expanding flow configuration

The dependence of the induced morphological layer variations on the processing conditions and parameters during injection molding of polymers is analyzed through a robust numerical framework of the complete microinjection molding cycle. Predicted temperature, heat transfer and viscous dissipation, spherulite diameters, and shear rates provide sufficient clarifications to develop a deeper understanding of the complex evolution of the induced thicknesses of layers. The evolution of the structure of polyoxymethylene (POM) under strong strain rates and high thermal gradients is investigated while flowing along an expanding flow configuration composed of three steps of increasing thickness. High and low mold temperatures and injection velocity levels are tested according to the design of the experiment method (DOE). Morphological development in each zone was examined to provide the induced crystalline layer thickness in the longitudinal as well as the transverse directions using polarized light microscopy (PLM). The thickness of the layers strongly depends on the local thickness of the stepped‐part and on the abrupt dimensional changes. The variation of bulk tensile properties obtained by dynamic mechanical analysis (DMA) is related to the thermomechanical history experienced by the melt.