Multiphysics Simulation Model Research Articles

Influence of different vibration directions on the solder layer fatigue in IGBT modules

Insulated-gate bipolar transistor (IGBT) modules are extensively utilized in high-speed trains, ships, and electric vehicles. Compared to those used in power systems, IGBT modules in these applications are more susceptible to vibration effects on their reliability. This paper proposes a multi-physics field simulation method and a lifetime model for IGBT modules to assess the impact of different vibration directions on solder layer fatigue. Initially, a multi-physics field model of the IGBT module is developed, incorporating electrical, thermal, mechanical, and vibration coupling. The effectiveness of this multi-physics simulation model is verified by an experimental platform. Subsequently, the influence of different vibration directions on solder layer fatigue in the IGBT module is analysed, and a life model of the IGBT is proposed through simulation. Finally, a power cycling with a vibration environment experimental platform is established to validate the effect of vibration on solder layer fatigue in the IGBT module. The simulation and experimental results indicate that vertical vibration accelerates the solder layer fatigue of IGBT modules, and the lifetime of an IGBT module operating under vertical vibration at 30 Hz is about 15 % shorter than that of an IGBT module operating under power cycling alone. The error between the calculated results of the solder layer failure and the experimental result is <5 %.

MultIHeaTS: A Fast and Stable Thermal Solver for Multilayered Planetary Surfaces

A fully implicit scheme is proposed for solving the heat equation in 1D heterogeneous media, available as a computationally efficient open-source Python code. The algorithm uses finite differences on an irregular grid and is unconditionally stable due to the implicit formulation. The thermal solver is validated against a stiff analytical solution, demonstrating its robustness in handling stiff initial conditions. Its general applicability for heterogeneous cases is demonstrated through its use in a planetary surface scenario with nonlinear boundary conditions induced by blackbody thermal emission. MultIHeaTS's advantageous stability allows for computation times up to 100 times faster than Spencer’s explicit solver, making it ideal for simulating processes on large timescales. This solver is used to compare the thermal signatures of homogeneous and bilayer profiles on Europa. Results show that homogeneous materials cannot reproduce the thermal signature observed in bilayer profiles, emphasizing the need for multilayer solvers. In order to optimize the scientific return of a space mission, we propose a strategy made of three local time observations that is enough to identify bilayer media, for instance, for the next missions to the Jovian system. A second application of the solver is the estimation of the temperature profile of Europa’s near surface (first 10s m) throughout a 1 million yr simulation with varying orbital parameters. The probability distribution of temperature through depth is obtained. Among its various applications, MultIHeaTS serves as the core thermal solver in a multiphysics simulation model detailed in the companion article by C. Mergny & F. Schmidt.

LunaIcy: Exploring Europa’s Icy Surface Microstructure through Multiphysics Simulations

Abstract A multiphysics simulation model incorporating a sintering model coupled with the MultIHeaTS thermal solver was developed to study the evolution of icy moons’ microstructure. The sintering process is highly dependent on temperature, and this study represents the first attempt in planetary science to examine the coupled interaction between heat transfer and sintering. Our approach to ice sintering is based upon the literature while offering a refined description of the matter exchange between grains, bonds, and the pore space. By running the numerical framework, we simulate the evolution of ice microstructure on Galilean satellites, specifically tracking the changes in the ice grain and bond radii over time. LunaIcy, our multiphysics model, was applied to study the evolution of Europa’s ice microstructure over 1 million yr along its orbit, with a parameter exploration to investigate the diverse configurations of the icy surface. Our results indicate that effective sintering can take place in regions where daily temperatures briefly surpass 115 K, even during short intervals of the day. Such sintering could not have been detected without the diurnal thermal coupling of LunaIcy due to the cold daily mean temperature. In these regions, sintering occurs within timescales shorter than Europa’s ice crust age, suggesting that, in present times, their surface is made of an interconnected ice structure.

Thermal comfort driven space heating control via hierarchical state machine strategy interacting with multiphysics simulation

Improving energy efficiency of space heating systems is as important as adopting emerging clean energy technologies for decarbonising heating. While exploring strategies for reducing energy consumption, the space occupants’ expectations to thermal comfort should not be sacrificed. Conventional space heating control systems are often developed under the hypothesis of uniform temperature distribution in a bounded space and the heating system controller is primarily operated based on the information from the temperature sensor at a fixed position. That is, the measured temperature does not represent the temperature surrounding the occupant’s location. This paper explores a new control method; the heating system control is led by the occupant’s thermal experience, expressed by the temperature surrounding the occupant. A new hierarchical state machine control strategy interacting with a Multiphysics simulation model to dynamically estimate the temperature at the point of the occupant is developed. The accuracy of the Multiphysics simulation model is verified based on the corresponding experimental test room data. A co-simulation platform is built to allow COMSOL and SIMULINK to communicate in real-time for control strategy realisation. The experimental results show that the maximum and average mean square error between the measured and simulated temperature under different operating modes is less than 0.21℃ and 0.06℃, respectively. The simulation results indicate that energy consumption could be potentially reduced around 20% with an improved thermal comfort of the occupant by 30%, compared with the conventional fixed sensor control method.

Analysis and Optimization of Multi-Physical Field Coupling in Boom Flow Channel of Excavator Multiway Valves

The multiway valve is the core control element of the hydraulic system in construction machinery, such as excavators. Its complex internal structure, especially the flow channels, significantly impacts the machine’s efficiency and reliability. This study focuses on the boom flow channel of excavator multiway valves and establishes a multi-physical field coupling simulation model. We propose six key flow channel structural parameters and analyze changes in the valve’s flow field, temperature field, and structural field using orthogonal test simulation data. The range analysis method identifies the primary and secondary influences of structural parameters on pressure loss, temperature, stress, and strain. A multi-objective optimization model was developed using a neural network and the Non-dominated Sorting Genetic Algorithm II(NSGA-II), with pressure loss and maximum stress as the optimization objectives. The Pareto front solution set for key flow channel parameters was calculated. The optimization results showed a 9.0% reduction in pressure loss and a 40.7% reduction in maximum stress. A test bench verified the simulation model, achieving prediction accuracies of 94.8% for pressure loss in the inlet area and 92.3% in the return area. This method can provide a reference for the optimal design of the dynamic characteristics of high-pressure multiway valves.

Detachable holographic acoustofluidic chip for striped acoustic field modulation and particle manipulation

The development of detachable acoustofluidic devices is of great significance for disposable and cost-effective biological and chemical analysis. In this work, a highly integrated holographic acoustofluidic device based on acoustic holography and microfluidic chips was proposed to realize the modulation of striped acoustic field in microchannels. In the device, the chip is disposable and the transducer is reused. The acoustic hologram was fabricated by injection molding for efficient manufacturing and low cost. In addition, a multiphysics simulation model for holographic acoustofluidic chip was established to analyze the effect of acoustic field modulation and particle manipulation. Results showed that the acoustic pressure inside the microchannel of the device exhibits a clear striped distribution, and a linear arrangement of particles parallel and inclined to the extension direction of the channel wall can be achieved within 2 s. The distance between the arrangement lines in the target region was controlled at around 60 μm. The investigation of thermal effect validates the biocompatibility. The designed holographic acoustofluidic device presents a promising option for the manipulation, arrangement, and sorting of cells and other particles in microchannels.

Multi-factor coupling analysis of electric field distribution in electrochemical machining with electrolyte suction tool

Electrochemical machining (ECM) technology holds significant potential for applications in high accuracy engineering and manufacturing. To confine the electrolyte region during ECM and mitigate the effects of reaction products and heat generation, an electrolyte suction tool has been proposed. However, the complex electric field distribution on the anode surface during the application of pulse voltage, limits the further utilization of ECM with suction tool. A multi-physics simulation model is established to calculate the region of electrolyte confinement by the suction tool, current density distribution within the electrolyte region, and material removal. The model considers the combined effects of polarization and double layer, and all key parameters are calibrated through classical electrochemical testing experiments rather than fitted based on the predicted results. This study elucidates the transient response of current density on the anode surface during the application of pulse voltage. The simulation accuracy is validated by comparing experimental and simulated current waveforms, as well as material removal profiles under different pulse parameters and electrode shapes. This research is of great significance for improving surface precision and controllability of complex structures in ECM with suction tool, promoting its further application in the field of precision machining.

Reliability Assessment and Multi-Physics Simulation of Additively Printed Wearable Humidity Sensor with Super Capacitive Material for Astronaut in Extreme Condition

Abstract Additive technologies, such as aerosol jet printing, direct write printing are increasingly being used in the production of printed circuit boards because they eliminate the need for costly tooling, such as photomasks or etching containers. This is because additive methods allow for the direct deposition of printing materials onto a substrate. This versatility in a broad variety of applications allows engineers to create diverse applications, such as sensing devices with ECG sensors, pulse-oxygen sensors, galvanic skin response sensors, body temperature sensors, humidity sensors, and so on. Due to its potential for adaptability and integration, the development of additively printed humidity sensors has been the subject of several prior investigations. There are still issues with the reliability of current humidity sensor technology when flexing force is coupled with the humidity sensor. For the avoidance of stability issues, it is required to develop a better printing technique, process recipe, and sensing material encapsulation. In this research, the direct-write (D-write) printing approach with a nScrypt printer was employed to print the humidity sensor as a test vehicle in a laboratory setting. The sensor was characterized by analyzing the print recipe and its interaction with humidity in regards to resistance and humidity sensitivity. Additionally, the characterization of sensor accuracy, hysteresis, linearity, and stability in relation to temperature and humidity variation has been measured. Furthermore, a multi-physics simulation model was created in order to comprehend the electrochemical processes that occur when the humidity sensor is exposed to a very humid environment.

Effect of insulation materials and power on microwave heating characteristics of SiC susceptor under material–specific parametric conditions

High-quality microwave absorber materials play a crucial role in the efficient and uniform processing of variety of materials through microwave hybrid heating. Silicon carbide (SiC) is an excellent microwave absorber at room temperature, which enhances the heating rate of the target materials significantly. In the present study, effects of heat insulation materials and their configurations on microwave heating characteristics of SiC were investigated at different power levels. The responses were assessed in terms of the heating capability (maximum temperature achieved), radiation heat loss, temperature gradient, and heating uniformity under different parametric conditions. A 3D COMSOL Multiphysics simulation model, coupled with microwave heating and heat transfer module, was developed with surface-to-ambient radiation boundary conditions. Electromagnetic and thermal properties of the SiC utilized in the model were selected based on physical properties, such as porosity/density, particle size, and chemical composition of SiC. The model outputs were validated with experimental findings. Results showed that microwave heating characteristics were highly sensitive to the susceptor (SiC) properties, insulation materials and power levels. Insulation materials prevented heat losses significantly; at the same time, different insulation configurations altered the electrical field intensity distribution within the SiC sample, which affected the responses. Microwave power levels also influenced the responses and quantity of insulation required.

Modeling for the Fabrication Process of a ϕ1185 mm C/C Composite Thermal Insulation Tube in an Isothermal Chemical Vapor Infiltration Reactor

The large-size chemical vapor infiltration (CVI) of the carbon/carbon (C/C) composite thermal insulation tube is a key component for drawing large diameter monocrystalline silicon rods. However, the CVI densification process is complex, and the cost of experiment optimization is extremely high. In this article, a multi-physics coupling simulation model was established and validated based on COMSOL Multiphysics v.5.6 software to simulate the fabrication process of an isothermal CVI process for a Φ1185 mm C/C composite thermal insulation tube. The influence of process parameters on densification was explored, and a method of optimization was proposed. Our modeling results revealed that the deposition status in areas of low densification was effectively and significantly enhanced after process optimization. At the monitoring site, the carbon density was no less than 1.08 × 103 kg·m−3, the average density of the composite-material thermal insulation tube improved by 5.7%, and the densification rate increased by 26.5%. This article effectively simulates the CVI process of large-sized C/C composite thermal insulation tubes, providing an important technical reference scheme for the preparation of large-sized C/C composite thermal insulation tubes.

Numerical simulation and experimental investigation of the molten pool evolution and defects formation mechanism of Selective laser melted CuSn20/Diamond composites

Some defects such as small pores, thermal damage of diamond particle and micro-cracks between diamond and metal matrix existed in SLM-fabricated metal-bonded diamond tools. For further application, it is vital to understand the formation mechanism of such defects by SLM-fabricated parameters. In this work, a multiphysics field numerical simulation model based on computational fluid dynamics (CFD) was developed to investigate molten pool evolution and defects formation mechanism for SLM-fabricated CuSn20-bonded diamond composites. From simulation results, the metal particles melt and flow forward under the action of the laser. Also, the presence of diamond particles can obstruct the normal flow of melted CuSn20 fluid. Increasing the laser power can widen and stabilize the molten pool, however, exacerbate the thermal damage of diamond particles. Specially, the migration and marginalisation of the diamond particles during the formation of molten pool were found by simulation and experimental results. Unavoidably, there are obvious gaps in the interfacial bonding region of diamond and CuSn20 due to the comprehensive reasons of thermal gradient, differences in thermophysical properties of two materials and undergo continuous migration and rotational behavior of diamond particles. These findings have potential value for understanding and optimizing the process of SLM-fabricated metal-bonded diamond tools.

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

This paper provides a comprehensive analysis of recent advancements in additive manufacturing, a transformative approach to industrial production that allows for the layer-by-layer construction of complex parts directly from digital models. Focusing specifically on Directed Energy Deposition, it begins by clarifying the fundamental principles of metal additive manufacturing as defined by International Organization of Standardization and American Society for Testing and Materials standards, with an emphasis on laser- and powder-based methods that are pivotal to Directed Energy Deposition. It explores the critical process mechanisms that can lead to defect formation in the manufactured parts, offering in-depth insights into the factors that influence these outcomes. Additionally, the unique mechanisms of defect formation inherent to Directed Energy Deposition are examined in detail. The review also covers the current landscape of process evaluation and non-destructive testing methods essential for quality assurance, including both traditional and contemporary in situ monitoring techniques, with a particular focus given to advanced machine-vision-based methods for geometric analysis. Furthermore, the integration of process monitoring, multiphysics simulation models, and data analytics is discussed, charting a forward-looking roadmap for the development of Digital Twins in Laser–Powder-based Directed Energy Deposition. Finally, this review highlights critical research gaps and proposes directions for future research to enhance the accuracy and efficiency of Directed Energy Deposition systems.

A dual‐mode integration framework and application to agile feedback design of launch vehicles

AbstractIn recent decades, the design of complex systems like launch vehicles in the aerospace industry has presented engineers with challenges that go beyond system complexity. Issues such as time‐to‐market pressures and intricate industrial processes have underscored the increasing significance of agile design methodologies. Agile design is derived from the simplification of the design process and enhancing cross‐domain data transmission and feedback. While methods based on model‐based system engineering have improved iteration times in system architecture design, challenges persist in cross‐domain data transmission. Due to the diversity of complex system models and data, a single‐mode integration method is difficult to realize the data link construction of all tools used. To address this challenge, this paper proposes a dual‐mode data integration framework with expansibility, universality, and cost‐efficiency which leverages the benefits of Remote Procedure Call and Intermediate Exchange Module, addressing the challenge of constructing cross‐domain data links under single‐mode integration. In this study, two critical requirements of the first‐ and second‐stage separation systems, namely, weight and minimum separation gap, are selected for data feedback. A Modelica‐based multiphysics simulation model is developed in MWorks; visualization and computation of the minimum gap are carried out in CoppeliaSim. To bridge the gap between domain‐specific tools, Matlab and Functional Mock‐up Unit modules are introduced as middleware, facilitating data feedback linkage. The entire simulation process is orchestrated using activity diagrams in the MagicDraw tool. The study delves into the influence of critical design parameters, such as the initial angular velocity of separation and the thrust of the retro rocket, on the minimum separation gap. It provides an analysis of minimum separation gap variations under uncertain operating conditions and examines design margins. Significantly, the paper highlights the significance of controlling the initial angular velocity during separation and the reliability of the retro rocket, providing essential decision supports and valuable insights to agile the process of system design.

Optimizing the chemical vapor deposition process of 4H–SiC epitaxial layer growth with machine-learning-assisted multiphysics simulations

This work addresses a novel technique for selecting the best process parameters for the 4H–SiC epitaxial layer in a horizontal hot-wall chemical vapor reactor using a transient multi-physical (thermal-fluid-chemical) simulation model and combined with a machine-learning model. An experiment was performed to validate the feasibility of the numerical model. Secondly, a single-factor analysis was conducted to investigate the effects of process parameters, including the deposition temperature, inlet-flow volume, rotational speed of the susceptor, and cavity pressure, on the quality of the 4H–SiC epitaxial layer. Finally, a machine learning algorithm, the ant colony optimization-back propagation neural network (ACO–BPNN), was employed to develop the input/output model and optimize process parameters for obtaining a high-quality epitaxial layer and reducing the optimization cycle and costs. Notably, the optimized process was validated by real experiments, where the error between calculation and experiment is 4.03 % for deposition rate and 0.49 % for coefficient of variation, respectively. The results highlight the model as reliable and lay the foundation for the CVD growth of the 4H–SiC epitaxial layer.

Partial differential equation modelling of the solid–liquid phase process in iron sintering and interface control with backstepping method

Due to the highly continuous temporal and spatial distribution characteristics of the sintering process, the solid–liquid phase interface during sintering is uneven and discontinuous, which seriously affects the quality of sintered ore. In order to achieve real-time and effective control of the solid–liquid interface in the sintering system, this study proposes a spatiotemporally distributed partial differential equation (PDE) thermal system with Stefan interface boundaries. Slice the 3D sintering mixing space and establish a discrete 1D space multi-distributed system to achieve distributed control of the sintering thermal system. Based on this system, a distributed boundary controller is designed using the backstepping method to drive the solid–liquid phase interface to the desired position. This method fully adapts to the nonlinear problems of the sintering thermal system and can quickly respond to system changes. Based on real data from the sintering site, a multi-physics simulation model was designed to verify the correctness of the theoretical research. Comparing the simulation results with the actual sintering state shows that this control method can effectively control the position of the sintering solid–liquid interface, which plays a vital role in improving the quality of sinter and sintering efficiency.

Research on Three-Phase Wireless Power Transfer System

Aiming at the problems of low power, low energy transmission efficiency, and high stress in the circuit of a single-phase wireless power transfer system, this paper proposes a wireless power transfer (WPT) system with a three-phase angle difference of 120 degrees and establishes a COMSOL multi-physics simulation model for analysis. In this simulation model, the topology of the three-phase resonant compensation network is studied in detail, and the structure of the coupling coil is designed and adjusted. Compared with the single-phase system with the same environmental conditions, air gap, and operating frequency, the simulation results show that the proposed three-phase system can effectively reduce the magnetic flux leakage, reduce the stress in the circuit, and significantly improve the energy transmission efficiency. In order to verify the reliability of the simulation results, an experimental platform was built. The experimental results show that the efficiency and coupling degree of the new system are significantly improved at the resonant frequency of 47.5 kHz, and the stress in the circuit is also significantly reduced.

An experimental investigation and multiphysics simulation of thermoelectric temperature controller for AWG chips

The refractive index of silicon-based waveguide materials is highly sensitive to temperature and stress, and the effective refractive index of the waveguide varies with temperature changes. Thus, it is critical to reduce the temperature dependence of Arrayed Waveguide Grating (AWG) devices and to precisely control the center wavelength of AWGs. In this study, the thermoelectric cooler (TEC) was designed and fabricated to control the temperature of the thermal AWG chip, which did not require any material replacement or reprocessing of the AWG chip. Different magnitudes and polarities of voltage are applied to the TEC to regulate its operational state (heating or cooling). A multiphysics simulation model of a thermal AWG device is established and validated through transient and steady-state experiments. This study investigated the influence of different conditions (input voltage, environmental temperature) on the temperature and maximum stress of the AWG chip. A conformal TEC was designed and its performance was compared with that of the square TEC. The energy consumption of the conformal TEC was also tested and analyzed. The results show that in a 25 °C ambient environment, the TEC can control the temperature of the AWG chip in the range of 1.5–78.3 °C, significantly expanding the current operational temperature range of 65.0–85.0 °C when using Positive Temperature Coefficient (PTC) heaters. Under the same conditions, when using the conformal TEC as the temperature control device, the temperature gradient on the AWG chip is reduced by 1.37 °C during cooling and 2.80 °C during heating. The maximum stress value in the core layer is always lower, with a maximum reduction of 3.61 MPa. TEC can set the ideal operating temperature of the AWG chip according to the actual operating environment of the product, which reduces the energy consumption of TEC. A comparison is made between the average power consumption of the conformal TEC and the PTC heater under two operating conditions: a 25 °C constant-temperature environment and a natural environment. The average power consumption can be reduced by up to 97.87 % and 93.02 %, respectively. This study holds significant guidance for solving the temperature dependence problem of AWG devices and the application of thermoelectric coolers in the field of optical communication.

Simulation analysis on the synergistic effect of vegetation ashes and charged particles on the gap electric field distortion

Hill fires, a sort of ultra-natural disaster that poses a severe threat to the safe and stable operation of transmission lines, have become more frequent in recent years. Currently, the modeling research on the transmission line gap electric field distortion under hill fire conditions does not consider the synergistic effect of charged particles and ash particles, which would lead to the imperfect gap electric field distortion mechanism. Herein, a coupled multi-physics field simulation model of electric, thermal, fluid, chemical field and particle motion was constructed to analyze the electric field distribution and particle motion. Compared to the related simulation models, this study improves the simulation accuracy by around 407% by optimizing the structure and parameters of the simulation model. The FEM software COMSOL Multiphysics simulation results show that the percentage of ash entering the examined region of the AC conductor was 34.1% higher, and the percentage of connected ash was 45% higher, increasing the likelihood of gap breakdown compared to the DC conductor; the charge of ash (10−14 to 10−11) is significantly less than the saturation charge of ash (⩾10−3). Therefore, the charged particles change the motion characteristics of the ash primarily through the electric field force and dielectrophoresis force, while the ash-induced distortion of the electric field affects the spatial distribution of the charged particles, eventually, the background electric field undergoes significant distortion by the synergistic effect of the two. The results examine the inherent mechanism of gap electric field distortion at the microscopic level, which can provide theoretical support for understanding the transition phase of transmission line gaps from insulation to break down under hill fire conditions.

Numerical study on the performance, combustion characteristics and energy flow distribution of gasoline-powered vehicle under synthetic actual driving test cycle

In order to meet the requirements of vehicle performance prediction and optimization under actual urban road conditions, a synthetic actual driving test cycle (ADTC) is proposed to accurately predict the performance and energy distribution characteristics of vehicles. Meanwhile, a multi-physical field vehicle energy management simulation model is built and verified carefully. Thus, numerical analysis was conducted on the performance of vehicles under ADTC and the characteristics of energy distribution were revealed. The results show that, the brake thermal efficiency (BTE) of the engine under ADTC varies in the range of 14.88 %–30.54 %, that is lower than worldwide harmonized light vehicles test cycle (WLTC) and new European driving cycle (NEDC). Besides, the proportion of combustion loss is WLTC, ATDC and NEDC from the largest to the smallest, which is mainly related to the complexity of speed variation. Based on this, unlike traditional testing cycles, ADTC synthesized from local actual road test data can more accurately evaluate the actual performance of vehicles under local characteristic road conditions and provide guidance for deep optimization, which is beneficial for energy conservation and emission reduction.

Fractional-order non-ideal isolation transformer modeling and parameter estimation for flyback power converters

An accurate component modeling of power electronics converters is crucial to understanding their real performance. Thus, a fractional-order representation of energy storage components like inductors and capacitors could be helpful to refect the hidden dynamics of a power converter in voltage regulation tasks. This paper presents the fractional-order non-ideal modeling and behavioral matching of an isolation transformer used on a flyback converter. A multiphysics simulation model is built to replicate the flyback converter non-ideal dynamics. It is optimized to precisely refect the real converter response by testing various transformer configurations, including ideal, non-ideal, integer and fractional-order. The transformer parameters are adjusted using raw data from the physical power converter. Likewise, the fractional-order energy storage elements are represented using discrete circuit elements for its realization. The results obtained reveal that using a non-ideal fractional-order transformer on the flyback converter with a non-integer inductance provides the maximum ft for the power converter operation.