The effects of blast lag in abrasive jet machined micro-channel intersections

Abrasive jet micro-machining (AJM) uses compressed air carrying abrasive solid particles to micro-machine a variety of features into surfaces. If the feature sizes are less than the size of the abrasive jet footprint, then a patterned erosion-resistant mask is used to protect the substrate material, leaving exposed areas to define the features. Previous investigations have revealed a ‘blast lag’ phenomenon in which, for the same dose of abrasive particles, narrower mask openings lead to channels that are shallower than wider ones. Blast lag occurs when using AJM on brittle substrates because of the natural tendency to rapidly form a V-shaped cross-sectional profile which inhibits abrasive particle strikes on the narrow vertex at the feature centerline. In this paper, the blast lag phenomenon is studied when using AJM to machine a network of microfluidic channels. It is found that, in some cases, differences in blast lag occurring at channel intersections and within the channels themselves, can lead to channel networks of nonuniform depth. A previously developed surface evolution model is adapted to allow prediction of the onset of blast lag in the channels and intersections and thus explain these differences. Finally, methods to eliminate the differences are discussed.     

聚合物熔体微尺度剪切黏度测量方法与黏度模型

研究微尺度效应下聚合物熔体黏度时,发现不同入口修正方法获得的剪切黏度随特征尺寸变化的规律不同,这对于聚合物微成型理论和技术尤为重要。采用直径分别为1 000μm、500μm、350μm的毛细管口模,在相同试验条件下分别用零口模法和Bagley法两种入口修正方法,研究高密度聚乙烯(High density polyethylene,HDPE)、短链支化的聚丙烯(Polypropylene,PP)、聚甲基丙烯酸甲脂(Polymethylmethacrylate,PMMA)和聚苯乙烯(Polystyrene,PS)四种材料的剪切黏度变化规律。结果发现,两种方法获得的PMMA和PS黏度随口模直径变化的规律相反,指出传统入口修正方法在测量微尺度黏度时存在局限。基于入口收敛流动特征,提出一种考虑微尺度效应下压力影响的测量方法,并用该方法给出四种材料剪切黏度随口模直径变化的真实规律。试验剪切速度范围内,四种材料剪切黏度均随口模直径的减小而减小,平均变化幅度为9.9%～38.3%,并从分子结构角度揭示四种材料黏度变化程度不同的机理。基于黏度变化规律,采用唯象性方法建立适用于宏—微观尺度下的黏度模型。试验结果表明该模型的理论预测结果与试验结果平均误差小于3.7%,验证了模型的正确性和有效性。     

AC Electrokinetic Fast Mixing in Non-Parallel Microchannels

A novel ultra-fast micromixer of a quasi T-channel with electrically conductive sidewalls is presented here and some new phenomena in its mixing process are observed and reported. The mixing is about 10²–10³ times faster than that by purely molecular diffusion, and about 10² times faster than that in existing micromixers, which are based on the electrokinetic instability (EKI). Both parallel and non-parallel channel are investigated and compared by evaluating their mixing. Mixing behaviors in the microchannels are studied in terms of scalar concentration distributions. It is found that with a small angle (about 5° in this case) between the two electrodes sidewalls, mixing can be enhanced rapidly at even low AC voltage. The influence of the applied AC voltage phase shift between the two electrodes on the mixing process is also explored. The result reveals that the mixing is the strongest under a 180° signal phase shift. Fast mixing is also achieved under high AC frequency in this micromixer. Fluorescent micro particles are used to visualize the flow pattern for better understanding of the mixing enhancement mechanism. The design of this micromixer could provide new opportunity for applications where fast mixing is demanded.     

Nusselt number correlations for a microchannel heat exchanger hot water supplier with S-shaped fins

Using 3D-CFD code, Nusselt number correlations for a microchannel heat exchanger (MCHE) with S-shaped fins used for hot water suppliers are obtained through numerical experiments and then validated. The supercritical carbon dioxide working fluid is assumed to operate around the pseudo-critical point, where fluid properties change radically. Calculations with 20 different temperatures are executed to produce Nusselt number correlations for each side. The fluid inlet temperature in each calculation is defined as 2 °C lower or higher than the constant wall temperature, respectively, for cold and hot side simulations. The small temperature difference of 2 °C is sufficiently small to regard thermal–hydraulic properties as constant. A new integrating method using the correlations to calculate the heat-transfer-performance is proposed. The resultant heat-transfer-performance is compared with that of another numerical result, which is reduced from large geometry and integration. The results agree within 3% error; the calculation accuracy of the method is confirmed. Experimental results with MCHE verify the correlations. The difference is approximately 5%. Using few computer resources, these Nusselt number correlations and the heat-transfer-performance calculation methods using correlation information are sufficiently accurate to evaluate heat exchangers.     

Spatially resolved temperature measurement in microchannels

Non-intrusive local temperature measurement in convective microchannel flows using infrared (IR) thermography is presented. This technique can be used to determine local temperatures of the visualized channel wall or liquid temperature near this wall in IR-transparent heat sinks. The technique is demonstrated on water flow through a silicon (Si) microchannel. A high value of a combined liquid emissivity and substrate overall transmittance coupled with a low uncertainty in estimating this factor is important for quantitative temperature measurement using IR thermography. The test section design, and experimental and data analysis procedures that provide increased sensitivity of the detected intensity to the desired temperature are discussed. Experiments are performed on a 13-mm long, 50 μm wide by 135 μm deep Si microchannel at a constant heat input to the heat sink surface for flow rates between 0.6 and 1.2 g min⁻¹. Uncertainty in fluid temperature varies from a minimum of 0.60°C for a Reynolds number (Re) of 297 to a maximum of 1.33°C for a Re of 251.     

Slip flow in non-circular microchannels

Microscale fluid dynamics has received intensive interest due to the emergence of Micro-Electro-Mechanical Systems (MEMS) technology. When the mean free path of the gas is comparable to the channel’s characteristic dimension, the continuum assumption is no longer valid and a velocity slip may occur at the duct walls. Non-circular cross sections are common channel shapes that can be produced by microfabrication. The non-circular microchannels have extensive practical applications in MEMS. Slip flow in non-circular microchannels has been examined and a simple model is proposed to predict the friction factor and Reynolds product fRe for slip flow in most non-circular microchannels. Through the selection of a characteristic length scale, the square root of cross-sectional area, the effect of duct shape has been minimized. The developed model has an accuracy of 10% for most common duct shapes. The developed model may be used to predict mass flow rate and pressure distribution of slip flow in non-circular microchannels.     

Constructal design of forced convection cooled microchannel heat sinks and heat exchangers

Heat transfer from arrays of circular and non-circular ducts subject to finite volume and constant pressure drop constraints is examined. It is shown that the optimal duct dimension is independent of the array structure and hence represents an optimal construction element. Solutions are presented for the optimal duct dimensions and maximum heat transfer per unit volume for the parallel plate channel, rectangular channel, elliptic duct, circular duct, polygonal ducts, and triangular ducts. Approximate analytical results show that the optimal shape is the isosceles right triangle and square duct due to their ability to provide the most efficient packing in a fixed volume. Whereas a more exact analysis reveals that the parallel plate channel array is in fact the superior system. An approximate relationship is developed which is very nearly a universal solution for any duct shape in terms of the Bejan number and duct aspect ratio. Finally, validation of the relationships is provided using exact results from the open literature.     

Using microchannels to cool microprocessors: a transmission-line-matrix study

As microprocessors components density and clock frequency increase, so do heat dissipation. The heat results from Joule effect due to leakage currents in the components area or active region. This region is only few microns thick and can quickly reach destructing temperatures if heat is not quickly removed. On this critical issue depends the system reliability. The active region is separated from the ventilated heat sink by a silicon substrate and a metal integrated heat spreader, both hundreds of microns thick. This interface region is the microprocessor's heat transfer plate where heat exchange is achieved by conduction. Because of the localized heat source, the thermal spreading resistance of the interface region can be high. A novel way of spreading heat in that region is the use of microchannel arrays where an appropriate thermal compound or a phase change liquid can be trapped to increase heat transfer by conduction or to create micro-heat-pipes. Traditional cooling methods, with conventional and well optimised heat sinks, can then be used with less burden.In this paper, the Transmission-Line-Matrix (TLM) technique is used to simulate the effect of microchannels on the temperature distribution in the active region. To minimize the interface heat resistance various microchannel and patterns are examined. In this part of the work, the microchannels are filled with the heat spreader material copper or aluminium. The results show an improved thermal transient behaviour and a reduced active region temperature in steady state.     

A criterion for experimental validation of slip-flow models for incompressible rarefied gases through microchannels

This paper is devoted to analysing the friction factor for incompressible rarefied gas flow through microchannels. A theoretical investigation is conducted in order to underline the conditions for experimentally evidencing rarefaction effects on the pressure drop. It is demonstrated that for a fixed geometry of the microchannel cross-section, it is possible to calculate the minimum value of the Knudsen number for which the rarefaction effects can be observed experimentally, taking into account the uncertainties related to evaluation of the friction factor.     

On the formation of Taylor bubbles in small tubes

The formation of Taylor bubbles and resulting bubble lengths were studied in a ID vertical tube for air-water and air-octane systems. In the co-flow tube/nozzle arrangement two nozzle sizes were used as gas inlets. Superficial velocities varied between 0.001- for the liquid and 0.002- for the gas. Three different mechanisms of initial bubble formation were observed. Of the three mechanisms, mechanism 3 is periodic (with period consisting of a bubble and a liquid slug), reproducible and can be simply modelled. After initial bubble formation further modifications may occur in the formed bubble size by coalescence or pairing. Bubble pairing is encouraged by smaller nozzles and liquid flow rates, while coalescence is observed only for cases where non-Taylor bubbles form initially.Two simple models have been proposed, the first predicts the size of the Taylor bubbles formed by mechanism 3 while the second attempts to predict the condition for bubble pairing to occur. Reasonable agreement with experimental results validates the predictions of the first model for a strong dependence of the volume of Taylor bubbles formed on the gas and liquid flow rates, a moderate dependence on nozzle diameter and a weak dependence (if at all) on the surface tension of the liquid used. Mismatch with the experimental results is caused (at least in part) by the experimental setup where there was no perfect axial alignment of the gas inlet. The experiments also suffered from problems at the outlet at low flow rates where smooth bubble disengagement could not be ensured for long Taylor bubbles. The second model for pairing predicts its occurrence for concentric tube/nozzle arrangements as a function of flow rates and channel diameters. The model over-predicted the range of liquid flow rates at which pairing was observed experimentally, but it captured the form of the boundary between different bubble volume modification mechanisms when represented on superficial velocity graphs.