High precision self-alignment using liquid surface tension for additively manufactured micro components

Self-assembly of components using liquid surface tension is an attractive alternative to traditional robotic pick-and-place as it offers high assembly accuracy for coarse initial part placement. One of the key requirements of this method is the containment of the liquid within a designated binding site. This paper looks to expand the applications of self-assembly and investigates the use of topographical structures applied to 3D printed micro components for self-assembly using liquid surface tension. An analysis of the effect of edge geometry on liquid contact angle was conducted. A range of binding sites were produced with varying edge geometries, 45–135°, and for a variety of site shapes and sizes, 0.4–1 mm in diameter, and 0.5 mm × 0.5 mm–1 mm × 1 mm square. Liquid water droplets were applied to the structures and contact angles measured. Significant increases in contact angle were observed, up to 158°, compared to 70° for droplets on planar surfaces, demonstrating the ability of these binding sites to successfully pin the triple contact line at the boundary. Three challenging self-assembly cases were examined: (1) linear initial component misplacement >0.5 mm, (2) angular misplacement of components, and (3) misplacement of droplet. Across all three assembly cases the lowest misalignments in final component position, as well as highest repeatability, were observed for structures with actual edge geometries <90° (excluding 45° nominal), where the mean magnitude of misalignment was found to be 31 μm with 14 μm standard deviation.     

Designing and producing large-volume liquid gamma-ray standard sources for low radioactive pollution measurements of seawater samples by comparison between experimental and simulation results

In order to in-situ measurement of large volume water samples, using of a portable HPGe detector was considered. Because of necessity of efficiency calibration of the detector for the geometry (100 L), the large volume standard sources were prepared. Before making large volume standard sources (100 L), the Monte Carlo method has been applied in order to optimizing the calibration procedures and in agreement with experiment results, has been caused reducing the amount of produced radioactive wastes. First, the efficiency of the portable coaxial P-type HPGe detector for 1 L liquid standard sources in Marinelli beaker geometry was simulated. Then, the experimental efficiency calibration was carried out using the detector for those 1 L liquid standard sources in Marinelli beaker geometry. The detector dead layer was determined by comparison of the simulation and experimental efficiency curve results. Then, a relation between simulation and experimental measurements, that is, between pulse-height per emitted particle, F8 tally, and estimated amount of spiked radioactive solution into the 1 L distilled water in Marinelli beaker was found. Then, the efficiency calibration of the large volume liquid standard sources was simulated. The estimated amount of spiking radioactive solution into the large volume distilled water (100 L) has been taken into account dividing experimental efficiencies (in Marinelli beaker) by the simulated efficiencies (in 100 L). Finally, by spiking the large volume distilled water with the radioactive solution, efficiency calibration of the potable HPGe detector for 100 L geometry was done.     

Upstream installation and misalignment effects on the performance of a modified electromagnetic flowmeter

The performance of a modified Danfoss 50 mm diameter electromagnetic flowmeter has been investigated when installed downstream from three different pipe diameters—50 mm, 55 mm and 45 mm. The effects of a 3 mm misalignment of the flowmeter, in both the vertical and horizontal planes, with respect to each of the three upstream pipe diameters has also been identified. The largest percentage errors are reported for the 45 mm upstream diameter pipe, with the flowmeter misaligned by 3 mm in the horizontal plane. The vertical and horizontal mean velocity and root-mean-square velocity profiles, measured within the flowmeter using laser Doppler anemometry, show significant variations in comparison with the ideal, fully developed profiles.     

Effects of flow patterns and salinity on water holdup measurement of oil-water two-phase flow using a conductance method

This research investigates the effects of flow pattern and salinity of oil-water two-phase flow on water holdup measurement using a conductance method. Firstly, vertical upward oil-water two-phase flow experiment is conducted in a 20 mm inner diameter (ID) pipe, in which the salinities of aqueous solutions are set as 151 ppm, 1003 ppm, 2494 ppm and 4991 ppm respectively. Experimental water-cut and mixture velocity are set as 80–100% and 0.0184–0.2576 m/s. In the experiment, three different flow patterns, i.e., dispersed oil-in-water slug flow (D OS/W), dispersed oil-in-water flow (D O/W) and very fine dispersed oil-in-water flow (VFD O/W) are observed and recorded by a high speed camera. Meanwhile, we collect the response of Vertical Multiple Electrode Array (VMEA) conductance sensor excited by a sine voltage signal. The result shows that, for VFD O/W, the water holdup from VMEA sensor shows a satisfied agreement with that of quick closing valve (QCV) method under certain salinities, i.e., 1003 ppm as well as 2494 ppm. For D OS/W flow and D O/W flow characterized by dispersed oil droplets with various sizes, considerable deviations of water holdup between VMEA sensor and QCV method under four kinds of salinity aforementioned are presented. Afterward, according to experimental analysis along with theoretical deviation, it is concluded that the deviation of the measurement system reaches its minimum when reference resistance in the measurement circuit and salinity of the aqueous solution satisfy constraint conditions, and the accuracy of water holdup using the conductance method can be improved through adjusting reference resistance to match the salinity of water phase. Finally, the recurrence plot algorithm is utilized to identify typical flow patterns mentioned above and it shows satisfied results on comprehending the discrepancies among different flow patterns, demonstrating that the recurrence plot algorithm can be effectively applied in flow pattern identification regarding oil-water flows.     

Measurement of seed spacing uniformity performance of a precision metering unit as function of the number of holes on vacuum plate

The objective of the study was to determine the seed spacing uniformity performance of a precision metering unit when vacuum plates with different number of holes were used. In order to meet this objective, the performances of vacuum plates with different number of holes were evaluated in the laboratory conditions by employing sticky belt tests and seed spacing values were measured computerized measurement system (CMS) for the cotton and corn seeds. Quality of feed index, multiple index, miss index as well as coefficient of precision (CP3) were considered as the performance indicators for precision seeding. The forward speed values were as selected as 1.0, 1.5 and 2.0 m s⁻¹ while vacuum plates with hole diameter of 3.5 mm for cotton and 4.5 mm for corn seeds were used. For both, cotton and corn seeds, five different vacuum plates (20, 26, 36, 52, and 72 holes) were considered in the experiments. In the experiments, vacuum pressure was applied at 6.3 kPa. Based on the findings in this work it appears that 1.0 and 1.5 m s⁻¹ of forward speed values were found to provide the highest performance levels for all vacuum plates. However such performance substantially decreased when forward speed increased to 2.0 m s⁻¹. In overall, the highest performance was determined when 26 and 36 holes were used for cotton and corn, respectively.     

A Pitot tube system for obtaining water velocity profiles with millimeter resolution in devices with limited optical access

An automated, miniature, S-type Pitot tube system was created to obtain fluid velocity profiles at low flows in equipment having limited optical access, which prevents the use of standard imaging techniques. Calibration of this non-standard Pitot tube at small differential pressures with a custom, low-pressure system is also described. Application of this system to a vertical, high-pressure, water tunnel facility (HWTF) is presented. The HWTF uses static flow conditioning elements to stabilize individual gaseous, liquid, or solid particles with water for optical viewing. Stabilization of these particles in the viewing section of the HWTF requires a specific flow field, created by a combination of a radially expanding test section and a special flow conditioner located upstream of the test section. Analysis of the conditioned flow field in the viewing section of the HWTF required measurements across its diameter at three locations at 1 mm spatial resolution. The custom S-type Pitot tube system resolved pressure differences of <100 Pa created by water flowing at 5–30 cm/s while providing a relatively low response time of ~300 s despite the small diameter (<1 mm) and long length (340 mm) of the Pitot tube needed to fit the HWTF geometry. Particle imaging velocimetry measurements in the central, viewable part of the HWTF confirmed the Pitot tube measurements in this region.     

Slug frequency in high viscosity oil-gas two-phase flow: Experiment and prediction

The number of slug units that traverses a particular point at a given time within a defined pipe cross-section is known as slug frequency. The behaviour of this critical parameter for two-phase flow in high viscosity oils is significantly different from those of conventional oils (of less than 1 Pa s). In this experimental investigation, new data on slugging frequency in high viscosity oil-gas flow are reported. Scaled experiments were carried out using a mixture of air and mineral oil in a 17 m long horizontal pipe of 0.0762 m ID. A high-speed Gamma Densitometer of frequency of 250 Hz was used for data acquisition over a time interval of 30 s. For the range of flow conditions investigated, increase in oil viscosity was observed to strongly influence the slug frequency. Comparison of the present data with prediction models available in the literature revealed discrepancies. A new correlation incorporating the effect of viscosity on slug frequency has been proposed for horizontal flow. The proposed correlation will improve the prediction of slug frequency in high viscosity oils.     

An ultra high-pressure test rig for measurements of small flow rates with different viscosities

Within the framework of a research project regarding investigations on a high-pressure Coriolis mass flow meter (CMF) a portable flow test rig for traceable calibration measurements of the flow rate (mass - and volume flow) in a range of 5 g min⁻¹ to 500 g min⁻¹ and in a pressure range of 0.1 MPa to 85 MPa was developed. The measurement principle of the flow test rig is based on the gravimetrical measuring procedure with flying-start-and-stop operating mode. Particular attention has been paid to the challenges of temperature stability during the measurements since the temperature has a direct influence on the viscosity and flow rate of the test medium. For that reason the pipes on the high-pressure side are double-walled and insulated and the device under test (DUT) has an enclosure with a separate temperature control. From the analysis of the first measurement with tap water at a temperature of 20 °C and a pressure of 82.7 MPa an extensive uncertainty analysis has been carried out. It was found that the diverter (mainly due to its asymmetric behaviour) is the largest influence factor on the total uncertainty budget. After a number of improvements, especially concerning the diverter, the flow test rig has currently an expanded measurement uncertainty of around 1.0% in the lower flow rate range (25 g min⁻¹) and 0.25% in the higher flow rate range (400 g min⁻¹) for the measurement of mass flow. Additional calibration measurements with the new, redesigned flow test rig and highly viscous base oils also indicated a good agreement with the theoretical behaviour of the flow meter according to the manufacturers׳ specifications with water as test medium. Further improvements are envisaged in the future in order to focus also on other areas of interest.     

Refined reconstruction of liquid–gas interface structures for stratified two-phase flow using wire-mesh sensor

Wire-mesh sensors (WMS), developed at HZDR [4], [13], are widely used to visualize two-phase flows and measure flow parameters, such as phase fraction distributions or gas phase velocities quantitatively and with a very high temporal resolution. They have been extensively applied to a wide range of two-phase gas–liquid flow problems with conducting and non-conducting liquids. However, for very low liquid loadings, the state of the art data analysis algorithms for WMS data suffer from the comparably low spatial resolution of measurements and from boundary effects, caused by e.g. flange rings – especially in the case of capacitance type WMS. In the recent past, diverse studies have been performed on two-phase liquid–gas stratified flow with low liquid loading conditions in horizontal pipes at the University of Tulsa. These tests cover oil–air flow in a 6-inch ID pipe and water–air flow in a 3-inch ID pipe employing dual WMS with 32×32 and 16×16 wires, respectively. For oil–air flow experiments, the superficial liquid and gas velocities vary between 9.2 m/s≤ν_SG≤15 m/s and 0.01 m/s≤ν_SL≤0.02 m/s, respectively [2]. In water–air experiments, the superficial liquid and gas velocities vary between 9.1 m/s≤ν_SG≤33.5 m/s and 0.03 m/s≤ν_SL≤0.2 m/s, respectively [17], [18]. In order to understand the stratified wavy structure of the flow, the reconstruction of the liquid–gas interface is essential. Due to the relatively low spatial resolution in the WMS measurements of approximately 5 mm, the liquid–gas interface recognition has always an unknown uncertainty level. In this work, a novel algorithm for refined liquid–gas interface reconstruction is introduced for flow conditions where entrainment is negligible.     

Research on signal amplitude of the Kármán vortex street in gas–liquid two-phase flow with high void fraction

Based on Biot–Savart law and single-phase flow Kármán vortex characteristics, flow field has been analyzed when gas–liquid flow past a fixed bluff body with high void fraction. Vortex signal characteristics have been studied for stratified two-phase flow on atmospheric conditions in a horizontal pipe. To discuss the relation between void fraction and vortex signal amplitude spectrum, this paper sets up the vortex-induced pressure field model for gas–liquid two-phase flow and gives the relationship between void fraction and relative amplitude spectrum of two-phase flow to single-phase flow. An algorithm is proposed for predicting the two-phase flow parameters. Experiments were performed using air–water as working fluid along with a test tube diameter of 50 mm, at gas volume flow rate of 20–68 m³/h, and void fraction of 0.9–1. The results indicate that calculations by the vortex-induced pressure field model on the amplitude spectrum of vortex signal are in good agreement with the experimental data, and relative errors of the algorithm predictions on gas volume flow rate and liquid volume flow rate are 0.08 and 0.56, respectively.     

Studying local liquid velocity in liquid–solid packed bed using the newly developed X-ray DIR technique

Combination of X-ray Digital Industrial Radiography (DIR) and Particle Tracking Velocimetry (PTV) techniques for local liquid velocity measurement (V_LL) has been newly developed and successfully applied for trickle bed reactor (TBR). The technique was validated against newly developed fiber optical probe technique. This work attempts to highlight the applicability of this newly developed technique on a liquid–solid packed bed reactor. In this work, liquid was represented by water and solids were represented by EPS beads. The EPS beads were chosen because of its low density property. Three superficial liquid velocities (V_SL) were applied to the system. The experiment was replicated four times. The digital industrial radiography (DIR) consists of a complementary metal oxide semiconductor (CMOS) digital detector and X-ray source. Results of this work suggest that the technique has been successfully applied and comparable with previous work that has been done in the literature. It also suggests that there will be a maximum measurable interstitial liquid velocity when it travel inside the packed bed. The measured V_LL can have a maximum range that is between 4 and 4.7 times that of its V_SL. For V_SL=0.42±±2%, the V_LL-Max is in between 1.7 cm/s and 1.9 cm/s, V_SL=0.84±±2%, the V_LL-Max is in between 3.6 cm/s and 4.0 cm/s, and for V_SL=1.11±±2%, the V_LL-Max is in between 4.3 cm/s and 4.8 cm/s.     

Measurement and statistical analysis toward reproducibility validation of AZ4562 cylindrical microlenses obtained by reflow

This paper presents the statistical analysis applied into the shape of microlenses (MLs) for validating the high-reproducibility feature of their fabrication process. The MLs were fabricated with the AZ4562 photoresist, using photolithography and thermal reflow processes. Two types of MLs arrays were produced for statistical analysis purposes: the first with a cross-sectional diameter of 24 μm and the second with a cross-sectional diameter of 30 μm, and both with 5 μm spacing between MLs. In the case of 24 μm diameter arrays, the measurements showed a mean difference in diameter of 2.78 μm with a standard deviation (SD) of 0.22 μm (e.g., 2.78 ± 0.22 μm of SD) before the reflow, and 2.34 ± 0.35 μm of SD after the reflow. For the same arrays, the mean difference in height obtained was, comparatively to the 5.06 μm expected, 0.76 ± 0.10 μm of SD before the reflow and 1.91 ± 0.15 μm of SD after the reflow, respectively. A mean difference in diameter of 2.64 ± 0.41 μm of SD before the reflow, and 1.87 ± 0.34 μm of SD after the reflow was obtained for 30 μm diameter MLs arrays. For these MLs, a mean difference in height of 0.71 ± 0.12 μm of SD before the reflow and 2.24 ± 0.24 μm of SD after the thermal reflow was obtained, in comparison to the 5.06 μm of height expected to obtain. These results validate the requirement for reproducibility and opens good perspectives for applying this fabrication process on high-volume production of MLs arrays.     

Tool wear analysis and improvement of cutting conditions using the high-pressure water-jet assistance when machining the Ti17 titanium alloy

This paper presents experimental results concerning the machinability of the titanium alloy Ti17 with and without high-pressure water jet assistance (HPWJA) using uncoated WC/Co tools. For this purpose, the influence of the cutting speed and the water jet pressure on the evolution of tool wear and cutting forces have been investigated. The cutting speed has been varied between 50 m/min and 100 m/min and the water jet pressure has been varied from 50 bar to 250 bar. The optimum water jet pressure has been determined, leading to an increase in tool life of approximately 9 times. Compared to conventional lubrication, an increase of about 30% in productivity can be obtained.     

Potential step study of electrooxidation of methanol in 1-butyl-3-methylimidazolium tetrafluoroborate

A potential step method was used to characterize the electrooxidation of methanol on a chemically modified electrode in an ionic liquid solvent. Two major findings were reported from this study. Firstly, the oxidation was dominant 2.2 s after the potential step. Before that, the double layer charging and adsorption were dominant. Therefore, there should be a waiting time of a few seconds if a methanol sensor is developed with a potential step method. Secondly, the oxidation of methanol on the electrode was diffusion controlled. The concentration of methanol affected the diffusion. The diffusion constant D₀ was 8.37 × 10⁻¹⁷ m²/s when the concentration was lower than 0.5 M and was 2.66 × 10⁻¹³ m²/s when the concentration was higher than 1.0 M. This suggests that the methanol concentration should be kept higher than a threshold in an ionic liquid based fuel cell.     

Drop swarm analysis in dispersions with incident-light and transmitted-light illumination

The new developed Optical Multimode Online Probe (OMOP) can process images from either incident-light illumination (also called epi-illumination) or transmitted-light illumination (also called trans-illumination). The probe has an outer diameter of 38 mm and the illumination is achieved by high performance Light Emitting Diodes (LEDs) with specifications of 1.96 mm² and 493 lm (251.53 lm/mm²) at an angular deviation of 0.37°. A camera probe is used with either an object-space telecentric (telecentricity <0.2°, 2437 mm virtual pupil distance) or entocentric objective (Köhler based illumination, 6238 mm virtual pupil distance). Using the telecentric mode, the particle distance independency is located within 20 mm while the focal depth is approximately 5 mm. The local resolution is between 20 and 30 μm, according to the used optics, with a standard deviation less than 4.5%. Maximum particle diameter is up to 5 mm while particles can reach up to 2 m/s as function of exposure. The basic distance transform approach with watershed segmentation for analysis of transmitted-light images gives deviations less than 5% at high particle densities and less than 2% at low ones. The error of false positives typically is below 5% while the error of wrong radiuses is below 1% for up to 90% of all droplets and below 5% otherwise. Up to five images per core and second (trans-illumination) can be analyzed automatically and online at densities up to 25% (trans-illumination, gap width less than 5 mm) 40% (object side telecentric epi-illumination, single probe) respectively.The advanced pre-segmentation approach based on the Random Forest Classifier (RFC) is used to perform the more complex image analysis with epi-illumination. As long as the quality of pre-segmentation is high enough, the classification results in images, which can be analyzed in the following distance transform approach. This is considerably depending on the quality of training the algorithm and recurring image features. Compared to the distance transform analysis at low densities the deviation increases. The RFC pre-segmented image gives an additional deviation of 1.1% (both in regard to the total amount of evaluated pixels) and a deviation of 12.9% in regard to the mean particle diameter. Below a particle size of 50 pixels the image analysis overestimates the actual number of particles due to the sensitivity of the Euclidian distance approach.     

Measurement of the viscosity of biodiesel by using an optical viscometer

In this paper, we report the characterization of the viscosity of biodiesel produced from jatropha curcas. The viscosity measurement has been carried out by using a modified falling ball viscometer as well as optical technology. The viscosity was measured from 28 to 70 °C, which is the interest for determining the quality of biodiesel. We found that the falling ball optical viscometer offers a resolution of a viscosity measurement of ±0.039 mPa s with a relative error of 1.47933%. The measurement process was compared with a commercial viscometer, and it has been demonstrated that the biodiesel produced in Chiapas has good quality.     

Uncertainty analysis of slot die coater gap width measurement by using a shear mode micro-probing system

A shear mode micro-probing system was constructed for gap measurement of a precision slot die coater with a nominal gap width of 90 μm and a length of 200 mm. A glass micro-stylus with a nominal tip ball diameter of 52.6 μm was oscillated by a tuning fork quartz crystal resonator with its oscillation direction parallel to the measurement surfaces. An on-line qualification setup was established to compensate for the influences of the uncertainty sources, including the water layers on the measurement surfaces. The measurement uncertainty of the measured gap width was estimated to be less than 100 nm.     

Application of Monte Carlo simulation for estimation of uncertainty of four-point roundness measurements of rolls

Large-scale rotors in the paper and steel industry are called rolls. Rolls are reground at regular intervals and roundness measurements are made throughout the machining process. Measurement systems for roundness and diameter variation of large rolls (diameter <2000 mm) are available on the market, and generally use two to four sensors and a roundness measurement algorithm. These methods are intended to separate roundness of the rotor from its movement. The hybrid four-point method has improved accuracy, even for harmonic component amplitudes. For reliable measurement results, every measurement should be traceable with an estimation of measurement uncertainty. In this paper, the Monte-Carlo method is used for uncertainty evaluation of the harmonic components of the measured roundness profile under typical industrial conditions. According to the evaluation, the standard uncertainties for the harmonic amplitudes with the hybrid method are below 0.5 μm for the even harmonics and from 1.5 μm to 2.5 μm for the odd harmonics, when the standard uncertainty for the four probes is 0.3 μm each. The standard uncertainty for roundness deviation is 3.3 μm.     

Influences of lubrication conditions and blank holder force on micro deep drawing of C1100 micro conical–cylindrical cup

Lubrication conditions and blank holder force (BHF) are two key processing parameters in deep drawing. This is more obvious in micro forming because of the miniaturization of the specimen size. Micro conical–cylindrical cups with internal conical bottom diameter of only 0.4 mm were well formed. The influences of lubrication conditions and BHF on micro deep drawing of micro conical–cylindrical cups were investigated using a micro blanking–deep drawing compound mold. Pure copper C1100 with a thickness of 50 μm, which was annealed at 450 °C for 2 h in vacuum condition, was chosen as the specimen material. The experiments were conducted on a universal testing machine with a forming velocity of 0.05 mm/s under 4 kinds of lubrication conditions and BHF. The experimental results showed that a micro conical–cylindrical cup with internal conical bottom diameter of only 0.4 mm was well formed, and the limiting drawing ratio (LDR) reached 2.1. The polyethylene (PE) film, which decreased the drawing force and increased the drawing ratio (DR), was superior to castor oil, petroleum jelly and dry friction, and can be chosen as a proper lubricant for micro deep drawing. The rim of the micro cup seriously wrinkled when BHF was less than 4.2 N. The bottom of the micro cup cracked when the BHF was larger than 5.6 N.     

Rolling contact fatigue using solid thin film lubrication

This paper addresses rolling contact fatigue (RCF) testing in ultra high vacuum (UHV) under high speed conditions. A ball–rod RCF test platform has been adapted for testing in UHV conditions that allows rapid accumulation of stress cycles, over 10 million cycles within 5 h of testing at 130 Hz rotation. The UHV environment and solid lubrication enables good vibration detection for the onset of spall. In this paper, approximately 0.2 μm of silver is applied to the balls and provides sufficient lubrication for up to 25 h of testing, or 50 million stress cycles in high vacuum at 130 Hz. Seventy-nine RCF tests using thin-film silver lubrication have been completed covering two ball sizes, and two rod and ball materials. 9.53 mm diameter Rex 20 steel and silicon-nitride (Si₃N₄) rods were tested against 7.94 mm diameter Rex 20 and 12.7 mm diameter M50 steel balls. It was found that ball size and material hardness did not affect the stress cycle life over a Hertzian contact stress range of 2.1–4.2 GPa and Rockwell C hardness range of 62–77. Rather, the key limiter to test length is lubrication depletion based on 79 tests and an average silver thickness of 0.2 μm. One of the two failure modes were observed for all tests: (i) early life spall of the silver coating, and (ii) depletion of silver lubrication followed by spall failure of both the ball and rod surfaces. A third-body storage model along with the Control Volume Fraction Coverage (CVFC) assumption and analysis was used to predict lubrication availability between asperities on the third body. There is good agreement between calculated and measured post-test lubrication thickness using the third-body storage model.