Search Results (17)

Crimped electrical connections must maintain electrical continuity and mechanical load transfer capability under combined environmental and operational stressors throughout their service life. Although the environmental durability of electrical connectors has been extensively studied, previous studies have mainly focused on material, environmental, or electrical effects in isolation, whereas the coupled influence of crimp geometry on electrical–mechanical degradation and contact evolution remains insufficiently understood. In this study, crimp geometry was isolated as the primary independent variable to investigate geometry-driven degradation behavior in crimped connections. Three crimp configurations (Type A, Type B, and Type C) were subjected to temperature cycling (−55 °C to +70 °C), high humidity (90–95% RH), and combined chemical–electrical loading conditions involving representative fluids and short-circuit current. Electrical and mechanical responses were evaluated using relative resistance variation ΔR (%) and tensile strength change ΔT (%), while factorial ANOVA quantified parameter contributions. The results indicate that crimp geometry dominates the response under thermal–humidity exposure, whereas the chemical exposure type becomes the governing factor for electrical degradation under coupled chemical–electrical conditions. SEM analysis reveals that geometry-dependent plastic deformation governs contact continuity and void formation, leading to a transition from continuous conductive networks to fragmented contact structures. These findings are further supported by FEM analyses, which provide qualitative insight into the deformation response as a function of the geometric parameters. This work presents a geometry-based experimental framework for understanding the degradation behavior of crimped bonding structures under dual-exposure test conditions. Full article

Cu/Ni/Ag composite materials are widely used in the manufacturing of electrical connector contacts due to their excellent electrical conductivity and good wear resistance. During hot plugging and unplugging operations, electrical connectors inevitably generate arc discharge, leading to melting, splashing, and erosion of the contact material, which severely threaten system reliability and service life. To investigate the arc behavior of Cu/Ni/Ag composite electrical connectors during plugging and unplugging, this paper establishes a multiphysics coupling model incorporating electric field, fluid heat transfer, and laminar flow based on the COMSOL simulation software (version 6.2). The model employs a multiphysics coupling approach, incorporating electric field, fluid heat transfer, and laminar flow, to systematically simulate the formation and evolution mechanisms of the arc during plugging and unplugging. The study focuses on analyzing the effects of plugging and unplugging speed, operating voltage, and arc gap distance on the arc, exploring the temporal and spatial evolution characteristics and distribution patterns of arc temperature. The simulation results reveal that the arc temperature follows a radially decreasing gradient, with the core region exceeding 10,000 K. When the operating voltage increases to 1000 V, the arc peak temperature rises to 1.3 × 10⁴ K. As the arc gap distance increases, the arc coverage area expands, and the peak arc temperature increases by approximately 2% to 8%. As the plugging/unplugging speed is increased to 500 mm/s, the peak temperature of the arc increases from 1.19 × 10⁴ K to 1.3 × 10⁴ K. The distribution characteristics of the magnetic field are clearly correlated with the arc temperature field and the electric field intensity distribution and the current density also exhibits typical constriction characteristics. Prolonged arc duration is correlated with an upward trend in peak temperature. Further analysis indicates that the temperature distribution characteristics of the arc are constrained by the competition mechanism of energy deposition and diffusion, while the evolution characteristics of the arc are regulated by the coupling effect of electromagnetic field and mechanical work. The research results provide a theoretical basis and simulation methods for the design of arc-resistant structures in Cu/Ni/Ag composite electrical connectors. Full article

A variety of Offshore Floating Photovoltaics (OFPVs) applications rely on the capacity of their floating support structures displacing in the shape of surface waves to reduce extreme wave-induced loads exerted on their floating-mooring system. This wave-adaptive displacement behaviour is typically realized through two principal design approaches, either by employing slender and continuously deformable structures composed of highly elastic materials or by decomposing the structure into multiple floating rigid pontoons interconnected via flexible connectors. The hydrodynamic behaviour of these structures is commonly analyzed in the literature using potential flow theory, to characterize wave loading, whereas in order to deploy such OFPV prototypes in realistic marine environments, a high-fidelity numerical fluid–structure interaction model is required. Thus, a versatile three-dimensional numerical scheme is herein presented that is capable of handling non-linear fluid-flexible structure interactions for Very Flexible Floating Structures (VFFSs): Multibody Dynamics (MBD) for modularized floating structures and floating-mooring line interactions. In the present study, this is achieved by employing the Smoothed Particles Hydrodynamics (SPH) fluid model of DualSPHysics, coupled both with the MBD module of Project Chrono and the MoorDyn+ lumped-mass mooring model. The SPH-MBD coupling enables modelling of large and geometrically non-linear displacements of VFFS within an Applied Element Method (AEM) plate formulation, as well as rigid body dynamics of modularized configurations. Meanwhile, the SPH-MoorDyn+ captures the fully coupled three-dimensional response of floating-mooring and floating-floating dynamics, as it is employed to model both moorings and flexible interconnectors between bodies. The coupled SPH-based numerical scheme is herein validated against physical experiments, capturing the hydroelastic response of VFFS, rigid body hydrodynamics, mooring line dynamics, and flexible connector behaviour under wave loading. The demonstrated numerical methodology represents the first validated Computational Fluid Dynamics (CFD) application of moored VFFS in three-dimensional domains, while its robustness is further confirmed using modular floating systems, enabling OFPV engineers to comparatively assess these two types of wave-adaptive designs in a unified numerical framework. Full article

In this study, a novel mechanical fluid–structure interaction (FSI) model is developed to analyze and discuss high-pressure hydrogen flow in a quick coupler under various operating conditions. The transient-state behavior is investigated with respect to different temperatures, hydrogen pressures, and O-ring thicknesses, which directly affect the compression and deformation of the seal. High-pressure hydrogen flow, which may lead to seal damage or failure, is of growing concern due to the increasing use of hydrogen in refueling stations, a sector expected to play a key role in the future of clean energy infrastructure. This study aims to introduce a coupled multiphysics approach by integrating the Finite Element Method (FEM) for solid mechanics with the Finite Volume Method (FVM) for hydrogen flow modeling. The coupling model shows nonlinear interactions between flowing hydrogen and the deformable polymer seal. The results of this work are expected to enhance both the design and performance of high-pressure hydrogen quick couplers, especially for applications in next-generation hydrogen refueling stations, where durability, sealing efficiency and safety are critical. Full article

While submissions of microfluidic-based medical devices to the Food and Drug Administration (FDA) have increased in recent years, leakage remains a common but difficult failure mode to detect in microfluidic systems. Here, we have developed a sensitive tool to measure and verify leakages ranging from 0.1% to 10% in leakage detection systems, which can then be used to detect leak in microfluidic devices. Our methodology includes an analytical model that applies hydrodynamic resistance using different fluid-contacting elements (e.g., tubing, junctions, and connectors) to tune the leakage rate based on the application-specific acceptance criteria. We then used three polymer-based microfluidic systems to target leakage rates of approximately 0.1, 1.0, and 10%. The experimental uncertainties in Polyether Ether Ketone (PEEK) tubing were 23.08%, 13.64%, and 1.16%, respectively, while the PEEK-Coated Fused Silica (PEEKsil) tubing system had errors of 0.00%, 0.72%, and 1.59%, respectively, relative to the theoretical values for the same target leak rates. The commonly used commercial grade Cyclic Olefin Copolymer (COC) microfluidic chips produced errors of 7.69% and 5.05%, respectively, for target leakage rates of 0.24% and 1.88%. We anticipate that the proposed bench test method can be useful for device developers as a verification tool for leakage detection systems before assessing flow-mediated leakage failure modes in microfluidic medical devices. Full article

Microscale electronics have become increasingly more powerful, requiring more efficient cooling systems to manage the higher thermal loads. To meet this need, current research has been focused on overcoming the inefficiencies present in typical thermal management systems due to low Reynolds numbers within microchannels and poor physical properties of the working fluids. For the first time, this research investigated the effects of a connector with helical geometry on the heat transfer coefficient at low Reynolds numbers. The introduction of a helical connector at the inlet of a microchannel has been experimentally tested and results have shown that this approach to flow augmentation has a great potential to increase the heat transfer capabilities of the working fluid, even at low Reynolds numbers. In general, a helical connector can act as a stabilizer or a mixer, based on the characteristics of the connector for the given conditions. When the helical connector acts as a mixer, secondary flows develop that increase the random motion of molecules and possible nanoparticles, leading to an enhancement in the heat transfer coefficient in the microchannel. Otherwise, the heat transfer coefficient decreases. It is widely known that introducing nanoparticles into the working fluids has the potential to increase the thermal conductivity of the base fluid, positively impacting the heat transfer coefficient; however, viscosity also tends to increase, reducing the random motion of molecules and ultimately reducing the heat transfer capabilities of the working fluid. Therefore, optimizing the effects of nanoparticles characteristics while reducing viscous effects is essential. In this study, deionized water and deionized water–diamond nanofluid at 0.1 wt% were tested in a two-microchannel system fitted with a helical connector in between. It was found that the helical connector can make a great heat transfer coefficient enhancement in low Reynolds numbers when characteristics of geometry are optimized for given conditions. Full article

A fully coupled electro-thermo-mechanical CFD model is developed and applied to illuminate the crucial factors influencing the overall performance of a solid oxide electrolysis cell (SOEC), particularly the configuration and geometry parameters of its inter-connector (IC), comprising ribs and channels. Expanding on a selected width ratio of 4:3, the gradient ribs/channels are further investigated to assess electrochemical and thermo-mechanical performance. It is elucidated that, while maintaining constant maximum temperature and thermal stress levels, employing a non-regular geometry IC with gradient channels may yield a 30% enhancement in hydrogen production. These nuanced explorations illuminate the complex interplay between IC configuration, thermal stresses, and electrolysis efficiency within SOECs. Full article

The focus of this paper is to investigate the effects of the addition of a connector between two serial microchannels. The idea of adding connector at the inlet of microchannels to enhance the random motion of molecules or nanoparticles in low Reynolds numbers was developed in our research group for the first time. It was experimentally determined that the shape of a connector between two microchannels has a significant impact on the enhancement of the random motion of molecules or nanoparticles. Consequently, the heat transfer coefficient is improved inside the second microchannel. The connector is large enough to refresh the memory of the fluid before entering the second channel, causing a higher maximum heat transfer coefficient in the second channel. It was also observed that the heat transfer coefficient can be increased at the end of the channel when the outlet temperature is relatively high. This may be explained by the fact that as temperature increases, the fluid viscosity tends to decrease, which generally drives an increase in the local random motion of base fluid molecules and nanoparticles. This causes an increase in the microchannel heat transfer coefficient. It was found that the addition of nanoparticles significantly modified the impact of the connector on the microchannel heat transfer coefficient. In addition, the effects of changing the Reynolds number and the shape of the connector were investigated through use of computational fluid dynamics (CFD) calculations. It was found that both factors have an important impact on the variation of velocity and enhancement of random motion of molecules and consequently significantly affect the heat transfer coefficient. Full article

We present a low-cost and simple method to fabricate a novel lock-and-key mixer microfluidics using an economic stereolithography (SLA) three-dimensional (3D) printer, which costs less than USD 400 for the investment. The proposed study is promising for a high throughput fabrication module, typically limited by conventional microfluidics fabrications, such as photolithography and polymer-casting methods. We demonstrate the novel modular lock-and-key mixer for the connector and its chamber modules with optimized parameters, such as exposure condition and printing orientation. In addition, the optimization of post-processing was performed to investigate the reliability of the fabricated hollow structures, which are fundamental to creating a fluidic channel or chamber. We found out that by using an inexpensive 3D printer, the fabricated resolution can be pushed down to 850 µm and 550 µm size for squared- and circled-shapes, respectively, by the gradual hollow structure, applying vertical printing orientation. These strategies opened up the possibility of developing straightforward microfluidics platforms that could replace conventional microfluidics mold fabrication methods, such as photolithography and milling, which are costly and time consuming. Considerably cheap commercial resin and its tiny volume employed for a single printing procedure significantly cut down the estimated fabrication cost to less than 50 cents USD/module. The simulation study unravels the prominent properties of the fabricated devices for biological fluid mixers, such as PBS, urine and plasma blood. This study is eminently prospective toward microfluidics application in clinical biosensing, where disposable, low-cost, high-throughput, and reproducible chips are highly required. Full article

Droplet-based microfluidic screening techniques can benefit from interfacing established microtiter plate-based screening and sample management workflows. Interfacing tools are required both for loading preconfigured microtiter-plate (MTP)-based sample collections into droplets and for dispensing the used droplets samples back into MTPs for subsequent storage or further processing. Here, we present a collection of Digital Microfluidic Pipetting Tips (DMPTs) with integrated facilities for droplet generation and manipulation together with a robotic system for its operation. This combination serves as a bidirectional sampling interface for sample transfer from wells into droplets (w2d) and vice versa droplets into wells (d2w). The DMPT were designed to fit into 96-deep-well MTPs and prepared from glass by means of microsystems technology. The aspirated samples are converted into the channel-confined droplets’ sequences separated by an immiscible carrier medium. To comply with the demands of dose-response assays, up to three additional assay compound solutions can be added to the sample droplets. To enable different procedural assay protocols, four different DMPT variants were made. In this way, droplet series with gradually changing composition can be generated for, e.g., 2D screening purposes. The developed DMPT and their common fluidic connector are described here. To handle the opposite transfer d2w, a robotic transfer system was set up and is described briefly. Full article

The design of surge protection devices is a practical issue for the management of pressurized pipeline systems. Depending on the flow status, dimension, material, and fluid properties of a particular pipeline, the generation of hydraulic transients and their interactions with surge protection devices have been explored considering different conditions for various pipeline systems. The resonance between the pipeline elements and surge energy absorption function of the hydraulic structure should be adaptively considered for each pipeline system. To comprehensively address surge generation and surge alleviating process, this study introduced dimensionless equations of fluid motion and continuity, and their solutions were developed in the dimensionless frequency domain. The impact of the surge tank, pressure accumulator, and its connector were also developed in terms of dimensionless operators. The impact of distinct flow conditions and pipeline properties was successfully addressed by an integrated parameter, dimensionless resistance, which also provided a unified condition for water hammer similarity in reservoir pipeline surge tank pipeline valve (RPSPV) systems. The development of dimensionless hydraulic impedance expressions along a pipeline system and its conversion into a response function provides a normalized pressure response in the dimensionless time domain. Excellent agreement was found between transient simulations using the developed method and those obtained using existing methods. The integration of a dimensionless approach into a metaheuristic engine provides a general platform for surge tank (ST) design in the comprehensive bounds of flow and pipeline conditions. Full article

Electrical contacts, although critically important for a wide range of applications, are susceptible to degradation due to fretting corrosion, especially when sliding and vibrations occur. To overcome fretting corrosion and sliding wear, lubricants are often used. However, the use of lubricants can cause other detrimental issues. Lubricants usually consist of non-conductive fluids such as hydrocarbons and fluorocarbons. Due to fluid dynamics, when sliding, vibration or other excitation occurs, these fluids can cause prolonged gaps between the conducting metal surfaces. Practically, this has been observed in data centers where vibrations due to technician maintenance or even earthquakes can occur. Depending on the viscosity and roughness of the surfaces, the time it takes these connector surfaces to return to solid conductive contact can be many seconds or longer. This work uses a novel theoretical model of the coupled fluid and solid mechanics between the rough metallic surfaces to evaluate these intermittent breaks in contact due to sliding. The influence of variation in lubricant properties, roughness, contact radius and contact force are considered by the model. Full article

The purpose of this paper is to investigate the effects of a connector between two microchannels, for the first time. A brief literature review is provided to offer a better understanding on the impacts of concentration and the characteristics of nanoparticles on thermal conductivity, viscosity, and, consequently, the heat transfer coefficient inside the microchannels. The given literature review aims to help engineer nanofluids to enhance the heat transfer coefficient inside the microchannels. In this research, Fe₃O₄ nanoparticles were introduced into the base liquid to enhance the heat transfer coefficient inside the microchannels and to provide a better understanding of the impact of the connector between two microchannels. It was observed that the connector has a significant impact on enhancing the heat transfer coefficient inside the second microchannel, by increasing the level of randomness of molecules and particles prior to entering the second channel. The connector would act to refresh the memory of the fluid before entering the second channel, and as a result, the heat transfer coefficient in the second channel would start at a maximum value. Therefore, the overall heat transfer coefficient in both microchannels would increase for given conditions. The impacts of the Reynolds number and introducing nanoparticles in the base liquid on effects induced by the connector were investigated, suggesting that both factors play a significant role on the connector’s impact on the heat transfer coefficient. Full article

In situ measurements are highly desirable in many microfluidic applications because they enable real-time, local monitoring of physical and chemical parameters, providing valuable insight into microscopic events and processes that occur in microfluidic devices. Unfortunately, the manufacturing of microfluidic devices with integrated sensors can be time-consuming, expensive, and “know-how” demanding. In this article, we describe an easy-to-implement method developed to integrate various “off-the-shelf” fiber optic sensors within microfluidic devices. To demonstrate this, we used commercial pH and pressure sensors (“pH SensorPlugs” and “FOP-MIV”, respectively), which were “reversibly” attached to a glass microfluidic device using custom 3D-printed connectors. The microfluidic device, which serves here as a demonstrator, incorporates a uniform porous structure and was manufactured using a picosecond pulsed laser. The sensors were attached to the inlet and outlet channels of the microfluidic pattern to perform simple experiments, the aim of which was to evaluate the performance of both the connectors and the sensors in a practical microfluidic environment. The bespoke connectors ensured robust and watertight connection, allowing the sensors to be safely disconnected if necessary, without damaging the microfluidic device. The pH SensorPlugs were tested with a pH 7.01 buffer solution. They measured the correct pH values with an accuracy of ±0.05 pH once sufficient contact between the injected fluid and the measuring element (optode) was established. In turn, the FOP-MIV sensors were used to measure local pressure in the inlet and outlet channels during injection and the steady flow of deionized water at different rates. These sensors were calibrated up to 140 mbar and provided pressure measurements with an uncertainty that was less than ±1.5 mbar. Readouts at a rate of 4 Hz allowed us to observe dynamic pressure changes in the device during the displacement of air by water. In the case of steady flow of water, the pressure difference between the two measuring points increased linearly with increasing flow rate, complying with Darcy’s law for incompressible fluids. These data can be used to determine the permeability of the porous structure within the device. Full article

Integrated microfluidic systems afford extensive benefits for chemical and biological fields, yet traditional, monolithic methods of microfabrication restrict the design and assembly of truly complex systems. Here, a simple, reconfigurable and high fluid pressure modular microfluidic system is presented. The screw interconnects reversibly assemble each individual microfluidic module together. Screw connector provided leak-free fluidic communication, which could withstand fluid resistances up to 500 kPa between two interconnected microfluidic modules. A sample library of standardized components and connectors manufactured using 3D printing was developed. The capability for modular microfluidic system was demonstrated by generating sodium alginate gel microspheres. This 3D printed modular microfluidic system makes it possible to meet the needs of the end-user, and can be applied to bioassays, material synthesis, and other applications. Full article