Macroscale Geometry Research Articles

Effect of Gas Flow Rates on Quality of Aerosol Jet Printed Traces With Nanoparticle Conducting Ink

AbstractThis paper focuses on the influence of carrier gas flow rate (CGFR) and sheath gas flow rate (SGFR) on the quality of conductive traces printed with nanoparticle inks using aerosol jet printing (AJP). This investigation was motivated by previous results of two AJP specimens that were printed at different gas flow rates and yielded significantly different thermal cycling durability lifetimes. A parametric sensitivity study was executed by printing and examining serpentine trace structures at 15 different combinations of CGFRs and SGFRs. The analysis included quantifying the trace's macroscale geometry, electrical properties, and micromorphological features. Interesting macroscale results include an increase in effective conductivity with increasing CGFR. At the microscale, image processing of high magnification scanning electron microscope (SEM) images of the printed traces revealed that agglomerations of silver clusters on the surface of traces became coarser at higher CGFR and also that agglomerates in the bulk were finer than those on the surface. Crystalline silver deposits were observed at all flow rates. In addition, cross sectioning of the printed traces showed higher incidences of buried cohesive cracking at higher gas flow rates. These cohesive cracks reduce the robustness of the traces but may not always be visible from the surface. The degree of cohesive cracking was seen to be broadly correlated with the coarseness of the surface agglomerates, thus suggesting that the coarseness of surface agglomerates may provide a visible surrogate measure of the print quality. The results of this study suggest that print quality may degrade as gas flow rates increase.

Using Multiscale Co-Simulation Modeling Technique to Understand the Transports Interaction inside Gas Channel, GDL, MPL, and CL during PEMFC Operations

The objective of this study is to use coupled simulation (co-simulation) approach to model the multidimensional/multiscale/multiphase polymer electrolyte membrane fuel cell (PEMFC) for enhancing the understanding of fuel cell performance and durability implications with structural, material properties and operational conditions. This work also provides the detailed knowledge of transports inside gas diffusion layer (GDL), microporous layer (MPL), and catalyst layer (CL). The local kinetic activity inside nanoscale CL has also been developed and modeled. These knowledge will contribute to enhance the catalyst activity at low current density and mass transport at high current density. This will enrich the development of novel structures that address local oxygen transport resistance in any kind of catalyst layer and this will be well aware of the urgent need for investigating multi-scale phenomena of a physical and electrochemical nature in a fuel cell. The Lattice Boltzmann Method (LBM) approach is extended to solve the mass transports and kinetic in the CL as shown in Figure 1. In this figure the catalyst layer is included into the model established in the previous work [1-3]. The nanoscale catalyst layer is attached into the microscale gas diffusion layer (GDL) and micro porous layer (MPL) as one computational domain. The macroscale geometry such as flow channel is continued to be computed by conventional CFD [4-5]. Figure 2 shows example of predictions of temperature distribution and oxygen mass fraction inside the cathode macroscale flow-field channel, microscale GDL/MPL, and nanoscale CL from this co-simulation approach.

Parametric control of fiber morphology and tensile mechanics in scaffolds with high aspect ratio geometry produced via melt electrowriting for musculoskeletal soft tissue engineering

Melt electrowriting (MEW) is an additive manufacturing technique that has the potential to create fibrous scaffolds that reproduce the scale and organization of collagen fiber networks in musculoskeletal soft tissues. For musculoskeletal soft tissue engineering, it is useful for scaffolds to have a high aspect ratio (length to width ratio of 5:1 or higher). However, the relationship between MEW process variables and the structural and mechanical properties of such scaffolds is not well understood. In addition, prior studies have cut samples from larger MEW structures, resulting in test specimens with discontinuous fibers. In this study, MEW scaffolds with low (square, 12 mm × 12 mm) and high aspect ratio (rectangular, 35 mm × 5 mm) macroscale geometries were fabricated at varying stage translation speeds or melt extrusion temperatures. Fiber morphology in both geometries and mechanical properties of the continuous rectangular structures were then quantified. Fiber diameter in both square and rectangular scaffolds generally decreased with increasing stage speed, but increased with melt temperature, though the effect of the latter was greater in square scaffolds. Interfiber spacing in both geometries was closer to the intended value as stage speed increased. Spacing became less accurate in square scaffolds with increasing melt temperature but changed little in rectangular scaffolds. Transverse fiber angle in rectangular scaffolds improved with increasing stage speed and had a median value within 1.4% of the intended angle at all temperatures. Finally, apparent tensile modulus in rectangular scaffolds decreased with increasing speed and temperature. These findings highlight the need to tailor MEW process parameters in scaffolds with high aspect ratio geometry in order to consistently generate specific structural and mechanical properties. Because of the potential to reproduce the structural anisotropy, fiber size, and mechanical properties of collagenous extracellular matrix, MEW structures are promising as musculoskeletal soft tissue scaffolds.

Liquid film on a hydrophobic radome or roof top in rain

The water film due to rain falling on a radome surface causes severe losses in radio wave transmission. Hydrophobic coatings have been applied as a remedy to reduce the film thickness and to minimize the losses. However, quantitative accounts of the wave scattering are mostly based on empirical estimates of the film thickness. We describe a fluid-mechanical theory for the film under steady rain falling on a textured surface formed by a square array of pillars. Assuming the water surface on top of the pillars to be in the Cassie–Baxter state, the analysis is carried out by making use of the sharp contrast of length scales between the film thickness and the radome radius. The textured surface is viewed as a periodic array of cells around pillars. The macro-scale flow is simple and linear but the micro-scale flow in a typical lattice period is fully nonlinear. These two problems are coupled and are solved iteratively to obtain the slip length and the spatial variation of the film thickness. Numerical results are presented to show the effect of solid fraction on local flow field, the slip length and the non-uniform reduction of the film thickness. To examine the influence of the macro-scale geometry on film formation, the theory is also modified for a hydrophobic roof top formed by two inclined planes.

Additively manufactured mesostructured MoSi2-Si3N4 ceramic lattice

Lattice structures, their shape, orientation, and density make the critical building blocks for macro-scale geometries during the AM process and, therefore, manipulation of the lattice structure extends to the overall quality of the final product. This work reports on manufacturing of MoSi2-Si3N4 ceramic lattices through a selective laser melting (SLM) approach. The strategy first employs the production of core-shell structured MoSi2/(10-13 wt%)Si composite powders of 3–10 μm particle size by combustion synthesis followed by SLM assembly of MoSi2/Si lattices and their further nitridation to generate MoSi2-Si3N4 mesostructures of designed geometry. Experimental results revealed that the volumetric energy density of SLM laser has remarkable influence on the cell parameters, strength, porosity and density of lattices. Under compressive test, samples sintered at a higher laser current demonstrated a higher strength value. Selective laser melting has shown its potential for production of cellular lattice mesostructures of ceramic-based composites with a low content of a binder metal, which can be subsequently converted into a ceramic phase to produce ceramic-ceramic structure.

Multiscale Fluid-Phase-Behavior Simulation in Shale Reservoirs Using a Pore-Size-Dependent Equation of State

Summary The phase behavior of reservoir fluids plays a fundamental role in predicting well performance and ultimate recovery. The uncertainty in phase behavior is currently one of the greatest challenges in developing unconventional shale resources. The complex phase behavior is attributed to the broad range of pore sizes in shale. In macroscale geometries such as fractures and macropores, the fluid behavior is bulk-like; in nanoscale pores, the fluid behavior is significantly altered by confinement effects. The overall phase behavior of fluids in porous media of mixed pore sizes is yet to be understood. In this paper, we present a study on the effect of pore-size distribution on the phase behavior of shale-reservoir fluids in a multiscale-pore system. The global fluid-phase equilibria among different sizes of pores are simulated. A pore-size-dependent equation of state (EOS) is used to describe the fluid by the confining pore diameter. The EOS confinement parameters for fluid/pore-wall surface interaction are determined by experimental results from differential-scanning calorimetry (DSC) and isothermal adsorption of species C1–14. The multiscale phase equilibria are simulated by directly minimizing the total Helmholtz free energy. A modified Eagle Ford oil is used for the case study. Constant-composition expansions (CCEs) of dual-scale (bulk and 15 nm) and triple-scale (bulk, 15 nm, and 5 nm) systems are simulated. The first bubble emerges from the bulk region at a lightly suppressed “apparent” bubblepoint pressure. Below the bubblepoint, the liquid saturation in the bulk region drops sharply, but the fluids in the nanopores are undersaturated throughout the multistage expansions. In the end, large amounts of intermediate-to-heavy hydrocarbons are retained in nanopores, implying a significant oil-recovery loss in shale. The confinement effect also leads to near-critical phase behavior in small-scale nanopores (<5 nm).

Localized impact stress concentrations in soft armors due to microscale projectile edge geometries

Although extensive focus has been placed on the ballistic performance of projectiles with certain macroscale geometries and dimensions, the microscale geometries are not as rigorously standardized. The localized stress concentrations arising from microscale geometries introduce multiaxial and locally concentrated stress states within the constituent material of the soft-armor target, which can result in premature failure that is not predicted with existing models. In this study, the microscale edge/corner geometries of right circular cylinder (RCC) projectiles are varied, and their respective ballistic performance was determined via experiments to examine the effects of the localized stress concentrations. Target panels were examined post-mortem and the effects of these localized stress concentrations on the failure modes were quantified. Experiments results indicate that stress concentrations drastically reduce the ballistic performance of the soft armor targets, and the fabric targets appear to fail without significant strain energy absorption.

Predictions of macro-scale fracture geometries from acoustic emission point cloud data in a hydraulic fracturing experiment

Observations of laboratory fracture testing by means of acoustic emission (AE) can provide a wealth of information regarding the fracturing process and the subsequent damage of the material or structure under load. A method for determining the structure of macro-scale fractures from a point cloud of AE events was developed and tested at the laboratory scale. An unconfined hydraulic fracturing experiment was performed on granite while monitoring acoustic emissions from six piezoelectric transducers on the surfaces of the specimen. The granite specimen dimensions were 30 × 30 × 25 cm3. The motivation of the AE analysis was to provide location information for a secondary wellbore placement which intersects the hydraulic fracture to complete a hydraulically connected binary well-hydraulic fracture system. Information gained from the 3D event source locations was used to optimize the location and orientation of secondary production well placement to intersect the induced hydraulic fracture. A direct method was developed to predict the location, orientation and shape of the hydraulic fracture from a dense cloud of AE events. The predicted fracture plane, which was assumed to be planar, was rotated in both the pitch and roll directions, while an average error of AE event distance between the assumed plane and the individual event locations was determined for each rotation iteration, resulting with a predicted fracture plane in the minimum error orientation. Post-test fracture observations were made and digitized in 3D space from coring and slabbing the granite specimen. The actual fracture observations were compared with the predicted fracture structure from AE and showed marked correlation. The simple method of determining macro-scale fracture location, orientation, and extents provided a useful tool for materials that exhibit large and disperse clouds of AE activity where coalesced fracture structure is not apparent.

From flat sheets to curved geometries: Origami and kirigami approaches

Abstract Transforming flat sheets into three-dimensional structures has emerged as an exciting manufacturing paradigm on a broad range of length scales. Among other advantages, this technique permits the use of functionality-inducing planar processes on flat starting materials, which after shape-shifting, result in a unique combination of macro-scale geometry and surface topography. Fabricating arbitrarily complex three-dimensional geometries requires the ability to change the intrinsic curvature of initially flat structures, while simultaneously limiting material distortion to not disturb the surface features. The centuries-old art forms of origami and kirigami could offer elegant solutions, involving only folding and cutting to transform flat papers into complex geometries. Although such techniques are limited by an inherent developability constraint, the rational design of the crease and cut patterns enables the shape-shifting of (nearly) inextensible sheets into geometries with apparent intrinsic curvature. Here, we review recent origami and kirigami techniques that can be used for this purpose, discuss their underlying mechanisms, and create physical models to demonstrate and compare their feasibility. Moreover, we highlight practical aspects that are relevant in the development of advanced materials with these techniques. Finally, we provide an outlook on future applications that could benefit from origami and kirigami to create intrinsically curved surfaces.

Mesoscale design of heterogeneous material systems in multi-material additive manufacturing

Mesoscale heterogeneous material systems are efficient and adaptive to real world environments, owing to the non-uniform stress fields that result from the convolution of component geometries, loading conditions, and environmental changes. With the advent of multi-material additive manufacturing, the production of heterogeneous material systems with a pre-defined mesoscale material distribution becomes feasible. This unlocks the design freedom at a characteristic length scale between the macroscale geometry and microstructures, but also calls for a new design framework to optimize the mesoscale material distribution in multi-material additive manufacturing. Here, we propose and demonstrate such a design framework by incorporating digital image correlation-based deformation mapping with 3D finite element modeling-based computational optimization. The constitutive behavior of each constituent material or their mixtures is calibrated by matching the local deformation data. The optimal mesoscale material distribution can then be determined using global optimization algorithms and validated experimentally.

Microstructural and geometric influences in the protective scales of Atractosteus spatula.

Atractosteus spatula has been described as a living fossil (having existed for 100 Myr), retaining morphological characteristics of early ancestors such as the ability to breathe air and survive above water for hours. Its highly effective armour consists of ganoid scales. We analyse the protective function of the scales and identify key features which lead to their resistance to failure. Microstructural features include: a twisted cross-plied mineral arrangement that inhibits crack propagation in the external ganoine layer, mineral crystals that deflect cracks in the bony region in order to activate the strength of mineralized collagen fibrils, and saw-tooth ridges along the interface between the two scale layers which direct cracks away from the intrinsically weak interface. The macroscale geometry is additionally evaluated and it is shown that the scales retain full coverage in spite of minimal overlap between adjacent scales while conforming to physiologically required strain and maintaining flexibility via a process in which adjacent rows of scales slide and concurrently reorient.

A Review of Three-Dimensional Printing in Tissue Engineering

Recent advances in three-dimensional (3D) printing technologies have led to a rapid expansion of applications from the creation of anatomical training models for complex surgical procedures to the printing of tissue engineering constructs. In addition to achieving the macroscale geometry of organs and tissues, a print layer thickness as small as 20 μm allows for reproduction of the microarchitectures of bone and other tissues. Techniques with even higher precision are currently being investigated to enable reproduction of smaller tissue features such as hepatic lobules. Current research in tissue engineering focuses on the development of compatible methods (printers) and materials (bioinks) that are capable of producing biomimetic scaffolds. In this review, an overview of current 3D printing techniques used in tissue engineering is provided with an emphasis on the printing mechanism and the resultant scaffold characteristics. Current practical challenges and technical limitations are emphasized and future trends of bioprinting are discussed.

A multi-scale finite element contact model using measured surface roughness for a radial lip seal

Historically, large computational requirements have left contact modeling approaches unable to combine multiple-length scale effects (comprised by the macro-scale geometry of the component and sub-micron geometry of the surface roughness) into a single deterministic analysis. This work presents a three-dimensional, multi-scale, finite element contact and deformation model for a worn-in radial lip seal. The model includes elastomer bulk geometry and apex surface roughness measured from an experimentally tested elastomer seal. The work describes the modeling method used to simulate the compressed state of the seal. A statistical parameter analysis of both the compressed and uncompressed surface roughness was performed. Results are presented and discussed with respect to their potential impact on modeling efforts and the operating conditions of the seal.

Structure of tracheae and the functional implications for collapse in the American cockroach

The tracheal tubes of insects are complex and heterogeneous composites with a microstructural organization that affects their function as pumps, valves, or static conduits within the respiratory system. In this study, we examined the microstructure of the primary thoracic tracheae of the American cockroach (Periplaneta americana) using a combination of scanning electron microscopy and light microscopy. The organization of the taenidia, which represents the primary source of structural reinforcement of the tracheae, was analyzed. We found that the taenidia were more disorganized in the regions of highest curvature of the tracheal tube. We also used a simple finite element model to explore the effect of cross-sectional shape and distribution of taenidia on the collapsibility of the tracheae. The eccentricity of the tracheal cross-section had a stronger effect on the collapse properties than did the distribution of taenidia. The combination of the macro-scale geometry, meso-scale heterogeneity, and microscale organization likely enables rhythmic tracheal compression during respiration, ultimately driving oxygen-rich air to cells and tissues throughout the insect body. The material design principles of these natural composites could potentially aid in the development of new bio-inspired microfluidic systems based on the differential collapse of tracheae-like networks.

Real-time rendering of refracting transmissive objects with multi-scale rough surfaces

This paper presents an efficient approach to render refracting transmissive objects with multi-scale surface roughness, under distant illumination. To correctly capture both fine-scale surface details and large-scale appearances, and enable real-time processing at various viewing resolutions, we first divide the surface roughness into three levels, namely, micro-scale, meso-scale and macro-scale. Each scale of roughness is modeled and evaluated using different strategies, and the overall roughness is approximated by their spherical convolution. Then, this representation is incorporated into a microfacet-based BTDF model, and multi-scale rough refractions are simulated on both front and back sides of an object as light enters and exits the object. In particular, non-linear filtering methods are applied to both macro-scale geometries and meso-scale bumps to reduce aliasing when viewed across a range of distances. Finally, experimental results illustrate that our approach produces resolution-dependent refraction effects that match super-sampled ground truth, while achieving a speed up of several orders of magnitude with hardware acceleration.

Using Topology Optimization to Numerically Improve Barriers to Reverse Engineering

Here explored is a method by which designers can use the tool of topology optimization to numerically improve barriers to reverse engineering. Recently developed metrics, which characterize the time (T) to reverse engineer a product, enable this optimization. A key parameter used in the calculation of T is information content (K). The method presented in this paper pursues traditional topology optimization objectives while simultaneously maximizing K, and thus T, in the resulting topology. New aspects of this paper include algorithms to (1) evaluate K for any topology, (2) increase K for a topology by manipulating macroscale geometry and microscale crystallographic information for each element, and (3) simultaneously maximize K and minimize structural compliance (a traditional topology optimization objective). These algorithms lead designers to desirable topologies with increased barriers to reverse engineering. The authors conclude that barriers to reverse engineering can indeed be increased without sacrificing the desirable structural characteristic of compliance. This has been shown through the example of a novel electrical contact for a consumer electronics product.

Meso-scale stress response of thin ceramic membranes with honeycomb support

Planar solid oxide fuel cells are made up of repeating sequences of electrolytes, electrodes, seals, and current collectors. For electrochemical reasons it is best to keep the electrolyte as thin as possible. However, for electrolyte-supported cells, the thin electrolytes are susceptible to damage during production, assembly, and operation. One of the latest generation electrolytes employs a meso-scale honeycomb layer to support thin, electrochemically efficient membranes. Using finite element analysis, a two-scale model computes distributions of first principal stresses throughout a representative unit cell of the meso-scale structure. Displacement at the macro-scale is informed by meso-scale geometry via a homogenized equivalent stiffness, while the stresses at the two scales are related via a scalar magnification factor. The magnification factor is computed for a variety of geometries and loading conditions. Physical specimens are measured in tension to obtain an experimental magnification factor which agrees well with the simulations. When both the stiffness and magnification factor for a given meso-scale pattern are known, the macro-scale geometry can be analyzed without revisiting the meso-scale model, thus reducing computational time and costs.

X-ray CT for quantitative food microstructure engineering: The apple case

Apple fruit is a major crop that can be supplied year-round due to low temperature storage in a controlled atmosphere with a reduced oxygen concentration and an increased carbon dioxide concentration. The low temperature and dedicated gas concentration levels are designed to provide optimal conditions that prevent ripening while maintaining the fundamental respiratory metabolism necessary for energy supply in the cells that ensures cell and tissue integrity during storage of the fruit. If the concentration of oxygen is too low or that of carbon dioxide too high, a fermentation metabolism is induced that causes the production of off-flavours, results in insufficient energy supply, leading to cell collapse and consequent tissue browning and cavity formation. The microstructural arrangement of cells and intercellular spaces in the apple create specific pathways for transport of the respiratory gasses oxygen and carbon dioxide. We used X-ray CT to characterise the changes in the microstructure of ‘Braeburn’ apple during the development of internal storage disorders. Multiscale modeling was applied to understand the changes in oxygen and carbon dioxide concentrations and respiration and fermentation rates in the apple during the disorder development in controlled atmosphere storage of ‘Braeburn’ apple fruit. The 3D microstructure geometries of healthy, brown tissue and tissue with cavities were created to solve the micro-scale gas-exchange model for O2 and CO2 using the finite volume method. The apparent gas diffusivities of the tissue were calculated and implemented in the macroscale geometry of healthy and disordered apples to study in detail the changes in the respiratory metabolism of the fruit.

Single- and Multi-Constituent Condensation of Fluids and Mixtures with Varying Properties in Micro-Channels

The relative magnitudes of the forces governing the transfer of heat, mass, and momentum during microscale condensation are fundamentally different from those in macroscale geometries, primarily due to the increasing importance of surface tension. A systematic series of experiments on condensation flow regimes, pressure drop, and heat transfer was conducted using innovative visualization and measurement techniques for condensation of synthetic and natural refrigerants and their azeotropic and zeotropic mixtures through micro-channels with a wide range of diameters (0.1 < DH < 5 mm), shapes, and operating conditions. These experiments resulted in flow-regime-based heat transfer and pressure drop models with very good predictive capabilities for such micro-channel geometries.

A multiscale method for micro/nano flows of high aspect ratio

We develop a new multiscale scheme for simulating micro/nano flows of high aspect ratio in the flow direction, e.g. within long ducts, tubes, or channels, of varying section. The scheme couples conventional hydrodynamic conservation equations for mass and momentum-flux with molecular dynamics (MD) in a unified framework. The method is very much different from common ‘domain-decomposition’ hybrid methods, and is more related to micro-resolution methods, such as the Heterogeneous Multiscale Method. We optimise the use of the computationally-costly MD solvers by applying them only at a limited number of streamwise-distributed cross-sections of the macroscale geometry. The greater the streamwise scale of the geometry, the more significant is the computational speed-up when compared to a full MD simulation. We test our new multiscale method on the case of a converging/diverging nanochannel conveying a simple Lennard–Jones liquid. We validate the results from our simulations by comparing them to a full MD simulation of the same test case.