Masoud Jabbari

Quasi-steady state power law model for flow of (La0·85Sr0·15)0·9MnO3 ceramic slurry in tape casting

Abstract One of the most common ways used to produce multilayer ceramics is tape casting. In this process, the wet tape thickness is one of the single most determining parameters affecting the final properties of the product, and it is therefore of great interest to be able to control it. In the present work, the flow in the doctor blade region of a slurry containing (La0·85Sr0·15)0·9MnO3 (LSM) material is described with a simple quasi-steady momentum equation in combination with an Ostwald–de Waele power law constitutive equation. Based on rheometer experiments, the constants in the Ostwald–de Waele power law are identified for the considered LSM material and applied in the analytical solution for the tape thickness. This solution is then used for different values of substrate velocity and doctor blade height and compared with experimental findings of the wet tape thickness, and good agreement is found.

Bingham plastic fluid flow model in tape casting of ceramics using two doctor blades – analytical approach

Abstract One of the most common processes used in manufacturing of multilayer ceramic packages, multilayer capacitors and large scale integration circuits is tape casting. In this process, the wet tape thickness is one of the single most determining parameters affecting the final properties of the product, and it is therefore of great interest to be able to control it. One way to control the tape thickness is to use a two doctor blade configuration in the tape casting machine. In this case, it becomes important to fix the height of the slurry in front of both doctor blades according to the desired tape thickness and casting speed (belt velocity). In the present work, the flow in both doctor blade regions of a slurry is described with a steady state momentum equation in combination with a Bingham plastic constitutive equation, and this is integrated to a closed form analytical solution for both reservoirs based on the desired wet tape thickness and casting speed. The developed model is used to investigate the impact of different material parameters and machine designs on the required slurry height. The solution is compared with experimental findings from the literature, and good agreement is found.

Modeling coupled heat and mass transfer during drying in tape casting with a simple ceramics-water system

ABSTRACT In many industrial processes such as in tape casting for electronics or in the food industry, drying is one of the determining physical phenomena. In this study, the evaporation of water from a ceramic–water mixture is investigated with the purpose of understanding the drying rate in the drying process of thin sheets produced by the tape casting process. The rate of mass loss in the drying process is a key factor that often is of interest, as it affects the final properties of the tapes. The 1D heat conduction equation is solved numerically to obtain the temperature field in a ceramic sheet. The change in the concentration of the water content is then used as the driving force for diffusive mass transport of the water. Mass–averaged thermal properties are assumed for the ceramic–water mixture in the initial stage. As the water evaporates, the thermal properties of the solid ceramic become more dominant since the fraction of water approaches zero. The developed model is used to simulate a simple test for the drying process. The drying rate is simply calculated by examining the water content in each time step. It is found that the mass loss due to the evaporation is increasing close to linearly with the drying time corresponding to an almost constant drying rate. However, the rate starts to decrease after some time in the simulation. It is also shown that too extensive surface drying results in a slow diffusion rate from the bottom, which in turn reduces the drying rate in general and hence is not favorable from a process viewpoint.

Numerical Modeling of Fluid Flow in the Tape Casting Process

The flow behavior of the fluid in the tape casting process is analyzed. A simple geometry is assumed for running the numerical calculations in ANSYS Fluent and the main parameters are expressed in non‐dimensional form. The effect of different values for substrate velocity and pressure force on the flow pattern as well as resultant tape thickness is evaluated. The analysis deals with the case of parallel blades and focuses on the ratio between the present hydrostatic pressure and the magnitude of the viscous force. A new non‐dimensional height for the tape thickness is proposed and the effect of the substrate velocity is evaluated. The results of the modeling show that a relatively uniform tape thickness can be achieved. Moreover, the results are compared with selected experimental and analytical data from literature and good agreement is found.

Humidity Buildup in Electronic Enclosures Exposed to Constant Conditions

Electronic components and devices are exposed to a wide variety of climatic conditions, therefore the protection of electronic devices from humidity is becoming a critical factor in the system design. The ingress of moisture into typical electronic enclosures has been studied with defined parameters such as openings in the enclosure (drain holes, intentional openings or leak) and sealing and casing material. Related corrosion reliability issues due to humidity buildup have been evaluated using an interdigitated surface insulation resistance pattern placed inside the enclosure during exposure. The moisture buildup inside the enclosure has been simulated using an equivalent RC circuit consisting of variables like controlled resistors and capacitors to describe the diffusivity, permeability, and storage in polymers.

Interface Behavior in Functionally Graded Ceramics for the Magnetic Refrigeration: Numerical Modeling

The active magnetic regenerator refrigerator is currently the most common magnetic refrigeration device for near room temperature applications, and it is driven by the magnetocaloric effect in the regenerator material. In order to make this efficient, a graded configuration of the magnetocaloric material is needed. Tape casting is a common process in producing functional ceramics, and it has recently been established for producing side-by-side (SBS) functionally graded ceramics (FGCs). The main goal of the present work is to study the multiple material flows in SBS tape casting and analyze the influence of the different material properties, i.e. the density and the viscosity, on the interface between the flows, since this is highly important for the efficiency of the device. The Newtonian flow behavior with relatively high viscosity is assumed for each fluid and used in the simulation with a commercial CFD code (ANSYS FLUENT). The results show that the density change does not affect the interface between the adjacent fluids. The viscosity of the fluids plays the most important role in the behavior of the interface. Moreover, increasing the viscosity difference of the adjacent flows, Δμ, leads to increasing the diffusive region between the two fluids.

Numerical simulation of transient moisture transfer into an electronic enclosure

Electronic systems are sometimes exposed to harsh environmental conditions of temperature and humidity. Moisture transfer into electronic enclosures and condensation can cause several problems such as corrosion and alteration in thermal stresses. It is therefore essential to study the local climate inside the enclosures to be able to protect the electronic systems. In this work, moisture transfer into a typical electronic enclosure is numerically studied using CFD. In order to reduce the CPU-time and make a way for subsequent factorial design analysis, a simplifying modification is applied in which the real 3D geometry is approximated by a 2D axial symmetry one. The results for 2D and 3D models were compared in order to calibrate the 2D representation. Furthermore, simulation results were compared with experimental data and good agreement was found.

Numerical modeling and experimental validation of microstructure in gray cast iron

To predict the amount of different phases in gray cast iron by a finite difference model (FDM) on the basis of cooling rate (R), the volume fractions of total γ phase, graphite, and cementite were calculated. The results of phase composition were evaluated to find a proper correlation with cooling rate. More trials were carried out to find a good correlation between the hardness and phase composition. New proposed formulas show that the hardness of gray cast iron decreases as the amount of graphite phase increases, and increases as the amount of cementite increases. These formulas are developed to correlate the phase volume fraction to hardness. The results are compared with experimental data and show reasonable agreement.

Mathematical modelling of coupled heat and mass transport into an electronic enclosure

In contrast to high fidelity CFD codes which require higher computational effort/time, the well-known Resistor-Capacitor (RC) approach requires much lower calculation time, but also with a lower resolution of the geometrical arrangement. Therefore, for enclosures without too complex geometry in their interior, it is more efficient to use the RC method for thermal management and design of electronic compartments. Thus, the objective of this paper is to build an in-house code based on the RC approach for simulating coupled heat and mass transport into a (closed) electronic enclosure. The developed code has the capability of combining lumped components and a 1D description. Heat and mass transport is based on a FVM discretization of the heat conduction equation and Ficks second law. Simulation results are compared with corresponding experimental findings and good agreement is found. Second simulation was performed to study the response of temperature and moisture inside an enclosure exposed to the B2 STANAG climatic cyclic conditions.

Estimation of water diffusion coefficient into polycarbonate at different temperatures using numerical simulation

Nowadays, many electronic systems are exposed to harsh conditions of relative humidity and temperature. Mass transport properties of electronic packaging materials are needed in order to investigate the influence of moisture and temperature on reliability of electronic devices. Polycarbonate (PC) is widely used in the electronics industry. Thus, in this work the water diffusion coefficient into PC is investigated. Furthermore, numerical methods used for estimation of the diffusion coefficient and their assumptions are discussed. 1D and 3D numerical solutions are compared and based on this, it is shown how the estimated value can be different depending on the choice of dimensionality in the model.