Thermal Mixing Research Articles

An NEA/OECD benchmark-experiment for the validation of CFD for mixing and thermal fatigue in T-junction dead leg flows

The current screening criteria for thermal fatigue used in isolated branch lines at nuclear power plants are based on simplified approaches, which, on one hand, tend to be overly conservative, and on the other hand, appear to miss important physics. This is demonstrated by the fact that a number of affected pipes were missed by the current screening methods.The purpose of the present work is to produce novel and accurate experimental data, which can be used for a benchmark of Computational Fluid Dynamics (CFD) in order to advance the prediction capabilities of thermal mixing and fatigue in dead leg T-junctions and improve the accuracy of the screening criteria. The ultimate value creation is increased safety and availability at nuclear power plants. This is of great interest and utmost importance to the nuclear reactor safety community.A new pressurized experimental setup of a T-junction has been designed and constructed for the purpose. The experimental setup, with a temperature difference of 120 °C, more closely resembles plant conditions than in earlier experiments. The boundary conditions in terms of the flowrates and temperatures are controlled and stable within their measurement uncertainty – a prerequisite for CFD-grade experiments.The novelty of the present work is measurements of the temperature fluctuations both in the near wall fluid mixing region and throughout the solid pipe wall material.It has been shown that the interaction between the swirl penetration of hot water and the stratified layer in the cold dead leg has an intermittent character and that random clusters of bursts of hot water penetrate into the stratification and the stagnant cold water below. The average time scale of this process is of the order of hundreds of seconds.The stratification between the hot and the cold water in the dead leg has also shown to have a low frequency oscillation of the order of 0.1 Hz, which wiggles in the circumferential direction. After hot water has penetrated downward and excited the instability, the temperature falls back to the initial one in a manner similar to a damped oscillation.The vertical temperature profiles have shown to be self-similar, for moderate temperatures, when scaled with the temperature difference between the hot and the cold water and with the penetration length.The penetration length increases with the velocity in the hot leg confirming earlier reported correlations.A small (less than 0.1 % of the hot main flow) cold leakage flow into the T-junction is sufficient to suppress the swirl penetration and substantially reduces the penetration length. However, the temperature fluctuations have a larger amplitude and range across the whole mixing zone. The fluid temperature fluctuations are shifted towards a more high frequency content, however, the low frequency nature of the swirl penetration is still present.The obtained novel dataset will be provided for a blind CFD benchmark exercise as part of an OECD/NEA project in 2023 and 2024.

Deciphering the origin and secondary alteration of deep natural gas in the Tarim basin through paired methane clumped isotopes

The Tarim Basin is one of the most complex, ancient, and petroliferous deep craton basins in the world. Multiple sets of source rocks, stages of tectonism, and episodes of hydrocarbon generation and accumulation complicate the formation and evolutionary processes of hydrocarbons in the basin, especially for the deeply buried petroleum system at >6000 m depth. Paired clumped isotopes (Δ13CH3D and Δ12CH2D2) allow the investigation of methane isotopic bond ordering, elucidating the methane generation mechanism and its post-generation processes, which can complement studies of the molecular and conventional stable isotopic compositions of gas hydrocarbons in constraining the origin and source of natural gas. This study focused on methane clumped isotopes, and chemical and conventional stable isotopic compositions of natural gas samples from four typical oil and gas regions of the Tarim Basin. Results indicate that these gases are thermogenic gases with relatively high stable isotopic δ values (i.e., −46.1‰ < δ13C–CH4 < −25.9‰, −184‰ < δD-CH4 < −140‰). Most exhibit equilibrium methane clumped isotope signatures at temperatures of 128–257 °C, consistent with the main oil-window to gas-window region. The clumped isotope apparent temperature of equilibrated methane was used to determine its formation temperature, which was applied for gas–source correlations and thermal maturity assessments of the natural gases based on the results of previous basin modeling. The clumped isotope compositions of two gas samples from the Keshen area of the basin are characterized by significant deficits in Δ12CH2D2 values but with similar Δ13CH3D values to those of other equilibrated gases there, indicating the possibility of methane bond re-ordering at high temperatures (>300 °C) exceeding the methane “closure temperature”. Non-equilibrium gases in the Tabei area yielded a plausible Δ13CH3D apparent temperature (<160 °C) with a pronounced deficit in Δ12CH2D2 values, possibly owing to irreversible chemical kinetic processes in thermal cracking of organic matter at early thermal maturity (Ro < 1.5‰) or mixing between thermogenic gases generated at two distinct temperatures (i.e., ∼200 °C and ∼120 °C). Equilibrium clumped isotope signatures also rule out the possible effects of secondary alteration on natural gases in the Hetianhe area that were previously considered in conventional isotope studies. Such findings demonstrate that methane clumped isotopes provide independent and effective indicators of gas–source correlations in deep basins while also elucidating secondary processes that are often under- or over-estimated in conventional stable isotope studies.

Two-dimensional turbulent thermal classical far wake

The two-dimensional turbulent thermal classical far wake is investigated. The turbulence is described by the Boussinesq hypothesis for the Reynolds stresses with Prandtl’s mixing length model for the eddy viscosity and eddy thermal conductivity. Two conservation laws are derived for the thermal boundary layer equations for the far wake using the multiplier method and two conserved quantities are obtained from the conserved vectors and boundary conditions. The Lie point symmetry associated with the momentum and thermal conserved vectors is derived. It is found that the momentum and thermal mixing lengths are proportional. In obtaining the invariant solution the cases ν≠0, κ≠0 and ν=0, κ=0 needed to be treated separately, where ν is the kinematic viscosity and κ is the thermal conductivity of the fluid. When ν≠0, κ≠0 the associated Lie point symmetry is determined in full but an analytical solution of the reduced ordinary differential equations could not be derived. The invariant solution is obtained numerically using a shooting method with the two conserved quantities as targets. The width of the wake is infinite. When ν=0, κ=0 the width of the wake is finite. In order to obtain the associated Lie point symmetry in full, Prandtl’s hypothesis that the mixing length is proportional to the width of the wake was imposed. The invariant solution is obtained analytically. The lines of constant mean temperature difference and the streamlines for the mean velocity deficit are plotted. The numerical and analytical solutions agree in the limit ν→0, κ→0.

Coupling of thermal convection and basin-basement fluid mixing is critical for the formation of unconformity-related uranium deposits: Insights from reactive transport modeling

Thermal convection and fluid mixing are involved in the formation of many mineral deposits, but their relationships and roles in mineralization remain poorly understood because they are generally investigated separately in different studies. Here we present a case study combining thermal convection and fluid mixing to examine the critical factors that controlled the formation of high-grade, world-class unconformity-related uranium (URU) deposits in the Athabasca Basin (Canada). Reactive transport modeling of various scenarios with different degrees of involvement of thermal convection and fluid mixing shows that significant URU mineralization occurs at the intersection of a basement fault with the basin-basement unconformity only if thermal convection and basin-basement fluid mixing take place concurrently. If there is no thermal convection in the basin, only sparse U mineralization occurs along the unconformity. If insufficient amount of reducing fluid is provided from the basement along the fault, no significant U mineralization occurs either. Furthermore, no significant U mineralization occurs if the U concentration in the basinal fluid is low. We conclude that the exceptionally rich U endowment in the Athabasca Basin is the result of coupling of three critical factors: high-permeability sandstone favoring thermal convection in the basin, ample supply of reducing agents by basement fluids along reactivated basement faults, and abundant U-rich basinal fluid available in the basin sequences. Similar coupling of fluid processes may be essential for the formation of other types of mineral deposits.

AgeSpectraAnalyst: A MATLAB based package to model zircon age distributions in silicic magmatic systems

In the last decade, improvements in the analytical precision achievable by zircon U-Pb geochronological techniques have allowed to resolve complexities of zircon crystallization histories in magmatic rocks to an unprecedented level. A number of studies have strived to link resolvable dispersion in zircon age spectra of samples from fossil magmatic systems to the physical parameters of their parent magma bodies. However, the methodologies developed have so far been limited to reproduce the effect of simple thermal histories on the final distribution of zircon ages. In this work we take a more nuanced approach, fine-tuning a thermodynamics-based zircon saturation model to predict the relative distribution of zircon ages in samples from silicic magma reservoirs experiencing open-system processes (e.g. heat/mass addition, mechanical mixing). Employing the MATLAB package (AgeSpectraAnalyst) presented in this contribution:•Users can forward model the effect that diverse thermal histories and mechanical mixing processes characteristic of silicic magma bodies have on zircon age distributions as measured by high-precision, chemical abrasion thermal ionization mass spectrometry (CA-ID-TIMS) U-Pb geochronology.•Zircon CA-ID-TIMS datasets from silicic magmatic systems can be easily compared with model output to gain semi-quantitative information on thermo-mechanical history of the system of interest.•We demonstrated (Tavazzani et al., in press) that distribution of high-precision zircon ages in crystallized remnants of shallow (∼ 250 MPa), silicic magma reservoirs can discriminate between systems that experienced catastrophic, caldera-forming eruptions and systems that underwent monotonic cooling histories.

Secondary flow and thermal field dynamics in a T-junction with an upstream elbow: A POD-aided, eddy-sensitized Reynolds-stress modeling study

The thermal mixing of the flow-crossing streams in a T-shaped pipe junction configuration with the main branch inflow forming an elbow is presently simulated by applying a RANS-based eddy-resolving model of turbulence. The low-temperature main stream enters the T-junction with a Reynolds number of Rem=107893 after passing through a 90o-turned elbow located upstream. The high temperature branch stream is injected perpendicularly into the main stream at a Reynolds number of Rem=5422. A significant difference between the flow velocities of the two streams leads to the formation of a characteristic mixing process resembling a reattached jet configuration. Of particular interest is the interference of the branch flow with the main flow characterized by secondary vortices – the so – called Dean vortices, that are convected from the curved main inlet generating a low-rank mixing structures in its wake. The reference LES-based (Large-Eddy Simulation) database is provided by Tunstall et al. (2016). The computational framework relying on the scale-adaptive turbulence modeling approach, introduced principally by Menter and Egorov (2010), is used to simulate the dynamics of large-scale turbulent structures with moderate spatial and temporal resolution requirements. The motion of unresolved subscale structures is described by an appropriately sensitized differential near-wall Reynolds stress model according to Jakirlić and Maduta (2015). In addition, Proper-Orthogonal Decomposition (POD) is used to analyze the prevailing flow and thermal field mechanisms. The results obtained show a reasonable level of agreement with the LES reference, both from the standpoint of first-order statistics and spectral reproduction of the dynamics of coherent structures.

On the role of low frequency modes in the thermal and momentum mixing in parallel plane jets

Parallel plane jet mixing has been the subject of extensive study and its physics are characterized well in literature. However, the physics of parallel plane jet mixing in relatively small confined regions is not well known. In this study we investigate the effects of re-circulatory flow on thermal and momentum mixing in confined parallel plane jets. Studying confined jet interaction is important for a variety of engineering applications. One of these applications is sodium cooled fast reactors (SFR). It is common in SFRs to have coolant stream mixing in a confined domain, often the upper plenum. The Reactor Cavity Cooling System (RCCS) facility at the University of Michigan models this problem in a simplified enclosure with isothermal parallel plane jets as the incoming coolant streams. A Large Eddy Simulation (LES) of this simplified plenum was developed using optimal boundary conditions, proven mesh convergence, and consistent resolution. This model was then validated against experimental results from the RCCS facility. After model validation, flow structures in the jet interaction were discerned by means of Proper Orthogonal Decomposition (POD). Comparison of 3D POD to a clipped 2D POD region reveals that re-circulatory flow can lead to dominant oscillations within the jet mixing region. Subsequently, Power Spectrum Density (PSD) and Continuous Wavelet Transforms (CWT) were used to ascertain frequency-based phenomena that might occur in this mixing region. Frequency analysis uncovered a dominant low-frequency oscillation in both velocity and temperature PSDs. These frequencies fall within the known ranges of thermal striping in sodium. The data generated in this study can be used for the benchmarking of less computationally intensive approaches. This data will be made available upon request to ebm5351@psu.edu.

Analysis of thermal hydraulic system code LOCUST V1.2 with ECC thermal mixing test facility

The safety injection (SI) system might be put into use, and the coolant at high temperature will mix with the supcooled water under Loss Of Coolant Accident (LOCA). The thermo-hydraulic phenomena associated with the thermal mixing of coolant and supcooled water will directly affect the judgment on core reflooding. China General Nuclear Power Group (CGN) independently developed and designed a thermal hydraulic system code named LOCUST, and the verification of thermal mixing models in LOCUST is necessary. This paper will introduce the thermal mixing tests at the T-junction based on Emergency Core Cooling System in Xi'an Jiaotong University (ECCS-XJTU) experimental facility, which were mainly conducted for the mixing between subcooled water injected from the SI pipe with a range of 25–125 kg/h in mass flow and the pure steam in the primary pipe with a range of 100–500 kg/h in mass flow. Besides, the fluid temperature and the dynamic vapor quality after mixing in tests are analyzed, and the simulations of 25 thermal mixing tests using the LOCUST 1.2 code are performed. The results show that the maximum relative error of LOCUST in mass flow of liquid is within 13.8 %, and the maximum relative error of LOCUST in temperature is within 8 %, which validates the reliability and accuracy of simulations of LOCUST for two-phase thermal mixing in LOCA.

Hierarchical MPC for a dynamic process system employing parametric global optimization strategy

The hierarchical decision making in process industries has been traditionally viewed as having a common objective, such as the overall cost, which needs to be optimized. However, a more appropriate approach is to formulate and solve hierarchical optimization and control problems. The solution algorithms for hierarchical optimization problems have been reported in the literature. The idea is to recast each optimization sub-problem in the hierarchy into a multiparametric programming problem, considering the variables of upper-level problems as unknown parameters. In this paper, explicit Model Predictive Control (MPC) and hierarchical optimization techniques, employing multiparametric programming, are combined for hierarchical MPC. The solution algorithm for hierarchical MPC is described in detail. Note that the solution to a hierarchical MPC problem is challenging, even for the simplest case of linear-quadratic objectives. Closed-loop simulations of a thermal mixing process, under two different hierarchical MPC formulations, are performed and the control performance is studied.

A case study of thermal mixing behavior of hot and cold fluid in T-junction with/without mixing jets

Three-dimensional numerical simulations are performed to study the turbulent mixing of hot and cold fluids at a T-junction with unique branch pipe extended mixing jets. The major aim of the current research is to compare the performance of two distinct designs for thermal mixing and flow characteristics of a T-junction. We investigate the effects of the momentum ratio and temperature difference of mixing fluids on temperature gradients for proposed configurations of T-junctions. The finding demonstrated that a T-junction with jets appears to mix hot and cold fluids more homogeneously. The addition of the mixing jets significantly lessens the internal wall's temperature gradients and improves the efficacy of thermal mixing. The thermal mixing efficiency for T-junctions with mixing jets increased by 25%, 42%, and 50%, respectively. At the same momentum ratio, the length of the thermal mixing in the T-junction with mixing jets is dramatically reduced by 77%, 79%, and 83%. The stress distribution is also determined using thermo-mechanical coupled analysis. The result shows the reduction in peak stresses substantially with the mixing jet T-junction. The current study will help the researcher to evaluate safety issues in high-temperature applications and better understand thermal mixing, flow characteristics, and thermal cracks.

Wind regimes above and below a dense oil palm canopy: Detection of decoupling and its implications on CO2 flux estimates

In tall vegetation canopies, calm weather conditions may result in the formation of an isolated below-canopy air layer. Especially during night, below-canopy carbon dioxide (CO2) fluxes may be concealed from above-canopy eddy covariance (EC) measurements, masking the magnitude of CO2 net ecosystem exchange (NEE). Particular attention to this “nighttime problem” needs to be paid in oil palm (Elaeis guineensis Jacq.) plantations, which can form a dense top canopy and which are grown in tropical regions where wind speeds are often low. Here, we investigated EC-based NEE measurements, wind and micrometeorological patterns, and LiDAR-derived terrain and canopy structure in a mature commercial oil palm plantation in the tropical lowlands of Jambi province, Sumatra, Indonesia. Over 3 years, we assessed the strength of turbulent and thermal mixing and tested five different methods to determine decoupling: (i) single-level (above-canopy) and (ii) two-level (above- and below-canopy) friction velocity (u*), (iii) above- and below-canopy standard deviation of the vertical wind (σw), (iv) bulk Richardson number (Rib), and (v) vertical turbulence intensity (ITurb). Our results show that decoupling is a common phenomenon in this plantation, with the two-level filters of σw and u* being most sensitive in its determination, showing ∼93% nocturnal decoupling. Decoupling is driven by the oil palm canopy structure, which develops a marked blocking layer at ∼10 m above the ground, high frequency of calm weather conditions, inverse temperature gradients and a terrain slope of 3° which was enough to create a thermally-induced drainage flow. Filtering NEE data, especially the two-level filters of σw and u*, challenged estimations of the plantation's CO2 balance due to high uncertainties in nocturnal respiration rates which could not be reduced by adding storage components to the measured fluxes highlighting the importance of additional below-canopy CO2 flux measurements, especially in such a weak-wind and dense-canopy tropical environment.

Eddy-resolving Reynolds-stress modelling of thermal mixing in cross-stream type T-junction configurations

The present work is concerned with the numerical simulation study of turbulent thermal mixing involving hot main and cold branch streams at high Reynolds numbers in two T-junction configurations that differ in flow rate ratio. This results in two topologically very different flow scenarios, classified as “wall-jet” and “impinging-jet” mixing processes. The underlying reference database originates from the well-known experimental WATLON study[16], dealing with the phenomena of thermal stripping in piping systems, and provides details on the configuration geometry and the associated boundary and operating conditions. The turbulence model used, implemented in the finite-volume-based numerical code OpenFOAM® [30], is a near-wall Reynolds stress model formulation appropriately sensitized by applying the scale-adaptive modeling strategy to enable its eddy-resolving capability [14]. The flow analysis includes the first- and second-order statistics, including both the flow and thermal fields, with the model results closely following the experimental reference. This refers to the global flow topology in terms of the flow separation pattern, both in terms of its shape and size, as well as to the individual mean velocity and temperature profiles and their fluctuating components. In addition, the spectral features of the flow are studied in detail using the proper orthogonal decomposition (POD) method to identify the low-rank structures whose frequency signatures contribute most to the phenomena of thermal stripping phenomena.

Study on targeted influence of annular porous media and rotating impeller on thermal mixing in T-junctions

T-junctions are utilized as the thermal mixing equipment of hot and cold fluids in chemical and nuclear industries. However, the flow/heat induced fatigue damage can be generated in the pipe wall of the T-junction by the intense velocity and temperature fluctuations. In this study, new targeted regulation methods consisting of the annular porous media and rotating impeller are proposed to regulate the thermal mixing performances of the T-junction. Then, the thermal mixing processes of T-junctions with/without porous media and impeller are evaluated by the large eddy turbulence model. The temperature field, velocity field, secondary flow intensity and performance parameters of T-junctions are compared. It is found that the annular porous media can targetedly inhibit velocity and temperature fluctuations in the near-wall zone, reduce the temperature gradient and decrease the secondary flow intensity. Besides, the rotating impeller can targetedly promote the thermal mixing in the mainstream zone, inhibit the thermal stratification and increase the secondary flow intensity. If the annular porous media and rotating impeller are utilized together, the effects can be superimposed, which is the recommended choice in this study. Finally, the results can be used as the guidelines for the thermal mixing enhancement and fatigue inhibition of the T-junction.

Convective heat transfer enhancement and entropy generation analysis for radiative flow of ferrofluid inside the enclosure with non-uniform magnetic field

The present work consists of investigating the thermal performance and entropy generation for the non-isothermal radiative-convective flow of magnetic-ferrofluid inside the cavity exposed to the variable magnetic field. The effects of Lorentz and Kelvin forces for magnetized liquid are associated with magnetohydrodynamic (MHD) and ferrohydrodynamic (FHD) are examined during this study. The penalty method is used to eliminate pressure terms from governing nonlinear system of partial differential equations, and then Galerkin finite element is utilized to reduce the system into a system of algebraic equations, which is then solved with the help of Newton Raphson method to obtain the required (unique) solution. The obtained results show that the thermal mixing and entropy generation increases with an increase in the magnetic number Mnf. The concentration of ferroparticles volume fraction (ϕ) from 0 to 0.05 increases the heat transfer rate by 62.78% and decreases the total entropy generation by 57.3%. The maximum 93.62% augmentation in the heat exchange rate is obtained at ϕ=0.05 and Mnf=103. The results of the present work can be used in obtaining geometric parameters and optimizing designs for effective energy transfer in chemical reactors, solar collectors, nuclear magnetic resonance imaging, heat exchangers, and dye removal from textile wastewater.

Evolution of Entropy Generation on Mixing Process Using a Novel Chaotic Micromixer

This study aims to compare numerically the laminar steady flow of shear-thinning non Newtonian fluids in novel chaotic micromixer. The process is verified for non-Newtonian flow in a complex geometry that is heated with a constant flux. The selected geometry produce secondary flow structures that greatly improve fluid dynamic performance. To measure this performance, the Poincaré map method is used for various cases of fluid power-law index in different geometries. In addition, thermal mixing behavior is studied for shear-thinning fluids in the chosen geometry with two different inlet temperatures.In different cases of fluid power-law indexes, the novel geometry resulted in an 82% increase in thermal mixing degree relative to the thermal mixing degree observed in the C-shaped and serpentine channels. The second law of thermodynamics is examined in terms of entropy generation caused by thermal and hydrodynamic processes, as a function of low rates of generalized Reynolds number and power-law index, while taking into consideration the effects of chaotic advection. As a result, the new configuration showed a significant improvement in the degree of mixing compared to other geometries considered, while also minimizing friction and thermal irreversibilities.

Heat transfer behaviour of mixing nano-non-Newtonian fluid in a chaotic micromixer

The hydrodynamic and thermal behaviors of Nano-Non-Newtonian fluids were examined using three-dimensional numerical simulations of a unique passive micromixer. To comprehend the quantitative and qualitative fluid fraction distributions with temperature homogenization, mass and heat transport properties of two heated fluids have been examined. For varied Reynolds numbers, the influence of fluid behavior and various Al2O3 nanoparticle concentrations on the pressure drop and thermal mixing capabilities were examined. Using CFD, the simulation of performance enhancement was run in intervals of varying Nanoparticle concentrations with Power-law index (n). In terms of fluid homogenization, the proposed micromixer demonstrated a mixing energy cost of 60% comparable to that realized for a recent micromixer (2021y). According to the analysis, for high nanofluid.

Magnetic field impact on double diffusive mixed convective hybrid-nanofluid flow and irreversibility in porous cavity with vertical wavy walls and rotating solid cylinder

Mixed convective heat transfer due to rotating surface has sustainable importance in improving cooling efficiency of thermal engineering equipment. In this investigation, hydromagnetic double diffusive mixed convection in a wavy porous cavity filled with hybrid nanofluid having rotating heat source is numerically studied. A solid cylindrical rotating heat source is positioned at the center of the wavy cavity. The fluid domain inside the cavity is heated from the rotating heat source and partially heated bottom wall. The governing partial differential equations are simulated using finite element method. The computational technique is validated performing rational comparisons. The results indicate that the pattern of streamlines circulation, isotherms and local entropy generation are significantly influenced with the rotating heat source. The flow velocity is observed increasing rapidly with cylinder rotation speed which is maximized with increasing cavity porosity and permeability but minimized with magnetic field impact and amalgamating hybrid nanoparticles. Heat transfer enhancement is found increasing by 682.07% with rotating heat source for varying Darcy number (Da = 10−4 to 10−1) in absence of magnetic field (Ha = 0) which reduces to 504.02% in presence of magnetic field (Ha = 100). Moreover, 45.62% heat transfer enhancement is achieved for varying of cavity porosity (ε = 0.3 to 0.9) which declines to 22.83% in presence of magnetic field (Ha = 100). In addition, 90.04% more heat transfer enhancement is estimated in hybrid nanofluid of 5% volume fraction than base fluid water. The entropy generations components are affected significantly with higher values of physical parameters. The Bejan number is found declining for all influential parameters studied. Accordingly, the study has significant impact on the controlling and optimizing of fluid flow and heat transfer in hybrid nanofluid filled improved designing and is applicable in improving the performance of thermal equipment such as high-performance heat exchangers, electronic device cooling, energy storage systems, thermal mixing, space thermal management, crystal growth, float glass production, solidifications, solar technologies, and reactor safety devices, etc.

Mechanism of pin thread and flat features affecting material thermal flow behaviors and mixing in Al-Cu dissimilar friction stir welding

Three different features of pin models in Al-Cu dissimilar friction stir welding processes are established to analyse the effects of threads and flats on the two-phase material thermal flow behaviors. Based on computational fluid dynamics (CFD), a simulation methodology that calculates pins with complex morphologies through an adaptive force boundary is proposed. The pin characteristics are gradually optimized from “conical contour” to “conical-thread” and then to “thread-flats”. For dissimilar Al-Cu materials, the physical properties are weighted by the volume fractions of two-phase materials in the mixing zone. To build a dynamic adaptive contact model that varies with the material flow state, the interfacial friction shear stress is calculated by using the relative slip between the tool and material. The linkage effects between the “thread + flats” on the dissimilar Al/Cu welding mechanisms are systematically analysed. The enhancing mechanisms of the thread and flats on the material flow are different. The thread mainly reinforces the longitudinal migration of the Al/Cu materials, which is perpendicular to the horizontal plane. The flats effectively expand the plastic flow range and material mixing zone on the horizontal plane. These flow expanding effects are observed on the Z = 1 mm plane since the radial range of material flow enlarges from 2 mm to 3 mm under the action of the flats, while the horizontal flow range undergoes little change with the thread. The coupled mechanism of the “thread + flats” shows 0.06 s periodic strengthening, and the fluctuation threshold of the material flow velocity is wider, significantly improving the upwards stirring of the bottom material. The enhanced horizontal flow and vertical migration are beneficial to the uniform dispersion of the second-phase material (Cu) and local material softening for the formation of Al-Cu heterogeneous joints. Moreover, the accuracy of the model is verified by comparing the simulated and experimental TMAZ boundaries.

Active vortex generation and enhanced heat transfer in a 3D minichannel by Onsager–Wien effect

A 3D numerical analysis of conjugate heat transfer in a rectangular minichannel in the presence of vortices generated by electric field induced Onsager–Wien effect has been performed. Fully coupled governing equations for flow, heat transfer, electric potential and charge transport are solved using the finite-volume framework of OpenFOAM®. Present study proposes a novel approach to increase mixing and heat transfer in a minichannel using the vortices generated by Onsager–Wien effect. Effects of the flow Reynolds number Re and electric Reynolds number ReEL on the thermo-hydraulic performance of the minichannel have been analyzed. The Onsager–Wien effect produces small flow vortices in the vicinity of thin plate electrodes flushed to the top and bottom walls of the channel. These vortices enhance the fluid mixing, deplete the thermal boundary layer and increase the heat transfer. The Onsager–Wien effect produces stable and prominent vortex structures at low Reynolds numbers. Whereas, the inertial force begins to dominate at higher Re and the vortices get smeared in the positive flow direction. In general, the heat transfer enhancement is directly proportional to the electric Reynolds number ReEL. A maximum of 48.25% increase in mean Nusselt number is observed within the parameter space considered herein. Results of this study indicate that, thermal boundary layer depletion and mixing by electric-field-induced Onsager–Wien effect substantially enhances the heat transfer performance of a minichannel, with a trivial additional electric power consumption. Results of the present numerical study will serve as a benchmark to design minichannel heat sinks with enhanced heat transfer based on thermal boundary layer depletion by application of weak/medium electric fields.

Circular Economy Electrochemistry: Recycling Old Mixed Material Additively Manufactured Sensors into New Electroanalytical Sensing Platforms.

Recycling used mixed material additively manufactured electroanalytical sensors into new 3D-printing filaments (both conductive and non-conductive) for the production of new sensors is reported herein. Additively manufactured (3D-printed) sensing platforms were transformed into a non-conductive filament for fused filament fabrication through four different methodologies (granulation, ball-milling, solvent mixing, and thermal mixing) with thermal mixing producing the best quality filament, as evidenced by the improved dispersion of fillers throughout the composite. Utilizing this thermal mixing methodology, and without supplementation with the virgin polymer, the filament was able to be cycled twice before failure. This was then used to process old sensors into an electrically conductive filament through the addition of carbon black into the thermal mixing process. Both recycled filaments (conductive and non-conductive) were utilized to produce a new electroanalytical sensing platform, which was tested for the cell's original application of acetaminophen determination. The fully recycled cell matched the electrochemical and electroanalytical performance of the original sensing platform, achieving a sensitivity of 22.4 ± 0.2 μA μM-1, a limit of detection of 3.2 ± 0.8 μM, and a recovery value of 95 ± 5% when tested using a real pharmaceutical sample. This study represents a paradigm shift in how sustainability and recycling can be utilized within additively manufactured electrochemistry toward promoting circular economy electrochemistry.