Fabrication of micro-channel arrays on thin metallic sheet using internal fluid pressure: Investigations on size effects and development of design guidelines

Micro-feature (channel, protrusion, cavity, etc.) arrays on large area-thin metallic sheet alloys are increasingly needed for compact and integrated heat/mass transfer applications (such as fuel cells and fuel processors) that require high temperature resistance, corrosion resistance, good electrical/thermal conductivity, etc. The performance of these micro-feature arrays mainly affects the volume flow velocity of the reactants inside the arrays which directly controls the rate of convection mass/heat transport. The key factors that affect the flow velocity include channel size and shape, flow field pattern, flow path length, fluid pressure, etc. In this study, we investigated these micro-feature arrays from the manufacturability perspective since it is also an important factor to be considered in the design process. Internal fluid pressure (hydroforming) technique is investigated in this study with the specific goals to, first, understand if the so-called “size effects” (grain vs. feature size) are effective on the manufacturability of thin metallic sheet into micro-channels, and second, to establish design guidelines for the micro-channel hydroforming technique for robust mass production conditions. Thin stainless steel 304 blanks of 0.051 mm thick with three different grain sizes of 9.3, 10.6, and 17.0 μm were used in hydroforming experiments to form micro-channels with the dimensions between 0.46–1.33 and 0.15–0.98 mm in width and height, respectively. Based on the experimental results, the effect of the grain size on the channel formability was found to be insignificant for the grain size range used in this study. On the other hand, the effect of the channel (feature) size was shown to dominate the overall formability. In addition, FE models of the process were developed and validated with the experimental results, then used to conduct a parametric study to establish micro-channel design guidelines. The results from the parametric study suggested that in order to obtain the maximum aspect ratio (height-to-width ratio) a small channel width should be used. Even though a large channel width would result in a higher channel height, the height-to-width ratio was found to be lower in this case. In addition, higher aspect ratio could be obtained by using larger corner radius (R_d), wider distance between adjacent channels (W_int), or less number of channels. On the other hand, the variation in draft angle (α) between 5° and 20° in combinations with the other channel geometries was found to be insignificant on the channel formability/height. All in all, these channel parameters (W, R_d, W_int, α, channel number, etc.) should be taken into account simultaneously in the design process in order to obtain such a design of the micro-feature arrays that would meet both performance and manufacturing requirements and constraints.     

Investigation of size effects on material behavior of thin sheet metals using hydraulic bulge testing at micro/meso-scales

Reliable material models are necessary for accurate analysis of micro-forming and micro-manufacturing processes. The grain-to-feature size ratio (d/D_c) in micro-forming processes is predicted to have a critical impact on the material behavior in addition to the well-known effect of the grain size (d) itself as manifested by the Hall–Petch relation. In this study, we investigated the “size effects” on the material flow curve of thin sheet metals under hydraulic bulge testing conditions. The ratio of the sheet thickness to the material grain size (N=t₀/d) was used as a parameter to characterize the interactive effects between the specimen and the grain sizes at the micro-scales, while the ratio of the bulge die diameter to the sheet thickness (M=D_c/t₀) was used to represent the effect of the feature size in the bulge test. Thin sheets of stainless steel 304 (SS304) with an initial thickness (t₀) of 51 μm and three different grain sizes (d) of 9.3, 10.6, and 17 μm were tested using five bulge diameters (D_c) of 2.5, 5, 10, 20, and 100 mm. A systematic approach for determining the flow curve of thin sheet metals in bulge testing was discussed and presented. The results of the bulge tests at different scales showed a decrease in the material flow curve with decreasing N value from 5.5 to 3.0, and with decreasing M value from 1961 to 191. However, as M value was decreased further from 191 to 49, an inversed relation between the flow curve and M value was observed; that is, the flow curve was found to increase with decreasing M value from 191 to 49, a new observed phenomenon that has never been reported in any open literature. New material models, both qualitatively and quantitatively, were developed to explain the size effects on the material flow curve by using the N and M as the characteristic parameters of relative size between the grain, the specimen (i.e., sheet thickness), and the part feature (i.e., bulge diameter). The explanation and prediction of the flow curve behavior based on these models were shown to be in good agreement with the bulge test results in this study and in the literature.     

Prediction of forming limits and parameters in the tube hydroforming process

Determination of process limits and parameters for hydroforming was conducted applying widely known plasticity, membrane and thin-thick walled tube theories. Analytical predictions were compared with experimental findings. Simple but useful analytical models to predict buckling, wrinkling and bursting as well as axial force, internal pressure, counter force and thinning in tube hydroforming were verified with experimental results.     

The use of FEA and design of experiments to establish design guidelines for simple hydroformed parts

We present models to predict the protrusion height of “Tee-shaped” hydroformed parts, both because this information is of direct relevance to engineers attempting to build such parts and also to illustrate an advantageous process for developing design guidelines for tube hydroforming (THF) in general. A newly proposed design of experiments technique, Low Cost Response Surface Method (LCRSM), was utilized to facilitate the economical prediction and optimization of this height as a function of geometrical parameters subject to thinning of the wall thickness at the protrusion region. The same methodology is also proposed for the economical investigation of other geometries and conditions. As a result of this investigation, not only were known and expected trends of effect of parameters verified, but also numerical values within a practical range of parameters at certain conditions were obtained. In addition, interactions between factors were also revealed as predicted. Moreover, this information was gained from a substantially reduced number of finite element analysis (FEA) simulations via LCRSM compared to standard response surface method (RSM) or factorial techniques, avoiding costly physical experimentation.     

Effect of manufacturing processes on contact resistance characteristics of metallic bipolar plates in PEM fuel cells

In this study, metallic bipolar plate (BPP) samples manufactured with stamping and hydroforming under different process conditions were tested for their electrical contact resistance characteristics to reveal the effect of manufacturing type and conditions. Punch speed and force in stamping, and pressure and pressure rate in hydroforming were selected as variable process parameters. In addition, two different channel sizes were tested to expose the effect of BPP micro-channel geometry and its consequences on the contact resistance. As a general conclusion, stamped BPPs showed higher contact conductivity than the hydroformed BPPs. Moreover, pressure in hydroforming and geometry had significant effects on the contact resistance behavior of BPPs. Short term corrosion exposure was found to decrease the contact resistance of bipolar plates. Results also indicated that contact resistance values of uncoated stainless steel BPPs are significantly higher than the respective target set by U.S. Department of Energy. Conforming to literature, proper coating or surface treatments are necessary to satisfy the requirements.     

Is there any interaction of resistin and adiponectin levels with protein‐energy wasting among patients with chronic kidney disease

The aim of this study was to evaluate the effects of adipocytokines including adiponectin, leptin, resistin, neuropeptide Y and ghrelin in chronic kidney disease (CKD) patients on appearance of protein‐energy wasting (PEW). One hundred fifty patients with mean age of 45.4 ± 15.9 years, without active infections or chronic inflammatory conditions were recruited into the study. Study groups were control group (consisting of 30 healthy volunteers with normal kidney functions), hemodialysis group, predialysis group, peritoneal dialysis group and kidney transplant group. Fasting morning serum leptin, ghrelin, acylated ghrelin, neuropeptide Y, adiponectin, resistin levels of all of the groups were measured. Anthropometric and nutritional assessments of all patients were obtained. Diagnosis of PEW was made according to definition recommended by the International Society of Renal Nutrition and Metabolism. Presence of PEW in hemodialysis (23.3%) and peritoneal dialysis (26.7%) groups were significantly higher than those of predialysis (3.3%), and transplantation (0%) groups. Adiponectin and resistin levels in predialysis, peritoneal dialysis and hemodialysis patients were significantly higher than control group (p: 0.0001). This study had given significant positive correlations between presence of PEW and serum resistin (r: 0.267, p: 0.001), and serum adiponectin levels (r: 0.349, p: 0.0001). There were no relationship between presence of PEW and ghrelin, acylated‐ghrelin, neuropeptide Y, and leptin levels of the groups. CKD patients except transplant patients had higher adiponectin and resistin levels than control group. PEW was found to be linearly correlated with resistin and adiponectin. High serum resistin and adiponectin levels might have a role in development of PEW among dialysis patients.     

The effect of nisin on L. monocytogenes in Turkish fermented sausages (sucuks)

Turkish fermented sausage (sucuk) is a traditional, well-known meat product in Turkey. The aim of this study was to evaluate the effect of different nisin concentrations on Listeria monocytogenes in experimentally contaminated sucuk. Analyses were performed on at 0, 1, 3, 5, 7, 10, 15, 20, 25 and 30days for L. monocytogenes and other microbiological parameters (Total mesophilic aerobic bacteria and lactic acid bacteria) and physico-chemical parameters (pH, a(w) and moisture content).The sucuk dough was contaminated with L. monocytogenes ATCC 7644 at a concentration of 10(6)cfu/g, and the dough was divided into six equal groups. Each group was treated separately with different nisin concentrations (0, 5, 10, 25, 50 and 100μg/g). No L. monocytogenes surviving cells were detected in groups which contained 100μg/g and 50μg/g nisin at day 20 and 25, respectively (p<0.001). In conclusion, the inhibition of L. monocytogenes in sucuk increases with the increasing concentrations of nisin.     

Operational modal analysis of a 2.5 MW wind turbine using optical measurement techniques and strain gauges

This work presents the results of in‐field tests performed on a 2.5 MW, 80 m diameter wind turbine. During the two test campaigns, dynamic response of the structure was monitored by using three different measurement systems, namely conventional strain gauges, photogrammetry and laser interferometry, whereas the turbine was both at parked condition and rotating. The recorded data were analysed by using an operational modal analysis algorithm based on the least square complex exponential method and several turbine parameters (eigenfrequencies and damping ratios) were extracted. The obtained system parameters were then qualitatively compared with the results presented in a study from literature, which includes both aeroelastic simulations and in‐field measurements performed on a similar size and capacity wind turbine. Copyright © 2012 John Wiley & Sons, Ltd.     

Assessment of extensive countrywide electrical power quality measurements through a database architecture

This paper describes countrywide electrical power quality (PQ) assessments of the Turkish Electricity Transmission System through a genuine PQ database. The database stores the output of mobile PQ measurement systems which are established at 172 transformer substations of the transmission system. At 601 measurement points in these substations, which are potentially critical in terms of PQ, measurements are carried out by the mobile systems for a period of 1 week. PQ parameters defined in the IEC-61000-4-30 standard in addition to power values are calculated from acquired raw data by the mobile-monitoring system and the resulting data are transferred to the PQ database. The database, based on a novel PQ data model, enables its users to take PQ snapshots of the transmission system countrywide and can be accessed through several interfaces including a visual query interface, a natural language interface, and a map interface. The overall PQ status of the measured points, representing the characteristics of the transmission system, is assessed through these interfaces and problematic points are determined while deriving important conclusions about the transmission system’s PQ behavior. Moreover, several novel PQ assessment methods are proposed and their applications on the PQ data are demonstrated especially through the map interface.     

Experimental investigations on wear resistance characteristics of alternative die materials for stamping of advanced high-strength steels (AHSS)

Newer sheet alloys (such as Al, Mg, and advanced high-strength steels) are considered for automotive body panels and structural parts to achieve lightweight construction. However, in addition to issues with their limited formability and high springback, tribological conditions due to increased surface hardness and work hardening necessitate the use of alternative microstructurally improved die materials, coatings, and lubricants to minimize the wear-related die-life issues in stamping of advanced high-strength steel grades. This study aims to investigate and compare the wear performances of seven different, uncoated die materials (AISI D2, Vanadis 4, Vancron 40, K340 ISODUR, Caldie, Carmo, 0050A) using a newly developed wear testing device. DP600 AHSS (advanced high-strength steel) sheets were used in these tests. It was concluded that the tested die materials demonstrated higher wear resistance performance when compared to the conventional tool steel AISI D2 die material.