As additive manufacturing grows as a cost-effective method of manufacturing, lighter, stronger and more efficient designs emerge. Heat exchangers are one of the most critical thermal devices in the thermal industry. Additive manufacturing brings us a design freedom no other manufacturing technology offers. Advancements in 3D printing lets us reimagine and optimize the performance of the heat exchangers with an incredible design flexibility previously unexplored due to manufacturing constraints.

In this research, the additive manufacturing technology and the heat exchanger design are explored to find a unique solution to improve the efficiency of heat exchangers. This includes creating a Triply Periodic Minimal Surface (TPMS) geometry, Schwarz-D in this case, using Mathematica with a flexibility to control the cell size of the models generated. This model is then encased in a closed cubical surface with manifolds for fluid inlets and outlets before 3D printed using the polymer nylon for thermal evaluation.

In the extent of this study, the heat exchanger developed is experimentally evaluated. The data obtained are used to derive a relationship between the heat transfer effectiveness and the Number of Transfer Units (NTU).The pressure loss across a fluid channel of the Schwarz D geometry is also studied.

The data presented in this study are part of initial experimental evaluation of 3D printed TPMS heat exchangers.Among heat exchangers with similar performance, the Schwarz D geometry is 32% smaller compared to a shell-and-tube heat exchanger.

The wettability of powders is an important characteristic for both industry and academia and is often described by the powder’s contact angle with a certain liquid. While there exist many ways to measure contact angle, it is a portion of the powder technology field that is not fully understood and requires more investigation and research. This study investigates two methods for measuring contact angle, the sessile drop method and the Washburn method, and looks to compare results to determine which method offers the most reliable data in terms of accuracy and repeatability. Two powders - microcrystalline cellulose and aluminum oxide - and three liquids - water, 50 cSt silicone oil, and 350 cSt silicone oil - were used to study the differences between the two measurement techniques as well as the effects of varying fluid viscosity on the measurements. It was found that the sessile drop method proved to be an ineffective method for measuring contact angle when liquid penetration into the powder occurred, as the contact angle changed while the drop penetrated. Initial results showed the contact angle for silicone oil on the powders to be greater than 90°, indicating nonwetting of the surface which was inconsistent with observations. The results from the Washburn method align better with other values in similar studies, but more study is needed to confirm the results gathered in this research.

3D printing has recently become a popular manufacturing process and the goal of the project was to take that process to the kitchen. This was done by utilizing existing knowledge of the culinary process of "spherification", by which a liquid is encapsulated in an edible shell, and combining it with the hydrogel research advancements in tissue engineering to make robust fibers. A co-flow nozzle was constructed and the two fluids needed for spherification were flowed in various configurations to create different fibers. By outlining a stability regime and measuring the outer diameters for both regular and reverse spherification, the optimal method of production and fibers that would be suitable for 3D printing were discovered. The results of the experiments can be used to begin 3D printing edible 2D patterns and eventually 3D structures.

Research on incorporating liquid metal into flexible substrates has resulted in a new avenue for research. Currently, the most promising technique performed was coating a cotton fiber in liquid metal and then using high heat to remove the fiber from the liquid metal without the use of flames or solvents. This is promising in that thin fibers could be coated to create the circuitry, then removed from the liquid metal. The remaining liquid metal could then be encased in a flexible polymer. This then sparked the idea of using a mortar and pestle to manually mix the liquid metal into the elastic substrate, in this case PDMS. Other materials can also be mixed in, such as graphite or alumina to create thermal interface materials (TIMs). These compounds are then poured into molds to cure, then are taken to be tested for thermal conductivity. The results have not yet returned, but this research will continue by changing the ratios of the materials in the TIMs as well as moving forward with encasing the remaining Galistan in elastomer once the fabric was removed through oxidation.

Advancements in thermal interface materials (TIMs) allows for the creation of new and more powerful electronics as they increase the heat transfer from the component to the heat sink. Current industrial options provide decent heat transfer, but the creation of TIMs with higher thermal conductivities is needed. In addition, if these TIMs are elastic in nature, their effectiveness can greatly increase as they can deal with changing interfaces without degradation of their properties. The research performed delves into this idea, creating elastic TIMs using liquid metal (LM), in this case galinstan, along with other matrix particles embedded in Polydimethylsiloxane (PDMS) to create an easy to use, relatively inexpensive, thermally conductive, but electrically insulative, pad with increased thermal conductivity from industrial solutions.

The pads were created using varying amounts of LM and matrix materials ranging from copper microspheres to diamond powder mixed into PDMS using a high-speed mixer. The material was then cast into molds and cured to create the pads. Once the pads were created, the difficulty came in quantifying their thermal properties. A stepped bar apparatus (SBA) following ASTM D5470 was created to measure the thermal resistance of the pads but it was determined that thermal conductivity was a more usable metric of the pads’ performance. This meant that the pad’s in-situ thickness was needed during testing, prompting the installation of a linear encoder to measure the thickness. The design and analysis of the necessary modification and proposed future design is further detailed in the following paper.

This thesis gives a detailed design process for a pulsed type thruster. The thrust stand designed in this paper is for a Pulsed Plasma Thruster built by Sun Devil Satellite Laboratory, a student organization at Arizona State University. The thrust stand uses a torsional beam rotating to record displacement. This information, along with impulse-momentum theorem is applied to find the impulse bit of the thruster, which varies largely from other designs which focus on using the natural dynamics their fixtures. The target impulse to record on this fixture was estimated to be 275 μN-s of impulse. Through calibration and experimentation, the fixture is capable of recording an impulse of 332 μN-s ± 14.81 μN-s, close to the target impulse. The error due to noise was characterized and evaluated to be under 5% which is deemed to be acceptable.

Durable, cost-effective, and environmentally friendly anti-icing methods are desired to reduce the icing hazard in many different industrial areas including transportation systems, power plants, power transmission, as well as offshore oil and gas production. In contrast to traditional passive anti-icing surfaces, this thesis work introduces an anti-icing coating that responds to different icing conditions by releasing an antifreeze liquid. It consists of an outer porous superhydrophobic epidermis and a wick-like underlying dermis that is infused with the antifreeze liquid. This bi-layer coating prevents accumulation of frost, freezing fog, and freezing rain, while conventional anti-icing surfaces typically work only in one of these conditions. The bi-layer coating also delays condensation on the exterior surface at least ten times longer than identical system without antifreeze.

It is demonstrated that the significant delay in condensation onset is due to the integral humidity sink effect posed by the hygroscopic antifreeze liquid infused in the porous structure. This effect significantly alters the water vapor concentration field at the coating surface, which delays nucleation of drops and ice. It was demonstrated that with a proper design of the environmental chamber the size of the region of inhibited condensation and condensation frosting around an isolated pore, as well as periodically spaced pores, filled by propylene glycol can be quantitatively predicted from quasi-steady state water vapor concentration field. Theoretical analysis and experiments revealed that the inhibition of nucleation is governed by only two non-dimensional geometrical parameters: the pore size relative to the unit cell size and the ratio of the unit cell size to the thickness of the boundary layer. It is demonstrated that by switching the size of the pores from millimeters to nanometers, a dramatic depression of the nucleation onset temperature, as well as significantly greater delay in nucleation onset can be achieved.

Many defense, healthcare, and energy applications can benefit from the development of surfaces that easily shed droplets of liquids of interest. Desired wetting properties are typically achieved via altering the surface chemistry or topography or both through surface engineering. Despite many recent advancements, materials modified only on their exterior are still prone to physical degradation and lack durability. In contrast to surface engineering, this thesis focuses on altering the bulk composition and the interior of a material to tune how an exterior surface would interact with liquids. Fundamental and applied aspects of engineering of two material systems with low contact angle hysteresis (i.e. ability to easily shed droplets) are explained. First, water-shedding metal matrix hydrophobic nanoparticle composites with high thermal conductivity for steam condensation rate enhancement are discussed. Despite having static contact angle <90° (not hydrophobic), sustained dropwise steam condensation can be achieved at the exterior surface of the composite due to low contact angle hysteresis (CAH). In order to explain this observation, the effect of varying the length scale of surface wetting heterogeneity over three orders of magnitude on the value of CAH was experimentally investigated. This study revealed that the CAH value is primarily governed by the pinning length which in turn depends on the length scale of wetting heterogeneity. Modifying the heterogeneity size ultimately leads to near isotropic wettability for surfaces with highly anisotropic nanoscale chemical heterogeneities. Next, development of lubricant-swollen polymeric omniphobic protective gear for defense and healthcare applications is described. Specifically, it is shown that the robust and durable protective gear can be made from polymeric material fully saturated with lubricant that can shed all liquids irrespective of their surface tensions even after multiple contact incidences with the foreign objects. Further, a couple of schemes are proposed to improve the rate of lubrication and replenishment of lubricant as well as reduce the total amount of lubricant required in making the polymeric protective gear omniphobic. Overall, this research aims to understand the underlying physics of dynamic surface-liquid interaction and provides simple scalable route to fabricate better materials for condensers and omniphobic protective gear.

Analytical solution of the pressure field for water uptake through a composite root, coupled with fully saturated soil is derived by using the slender body approximation. It is shown that in general, the resistance of the root and soil are not additive. This result can play a very important role in modelling water uptake through plant roots and determination of hydraulic resistances of plant roots. Optimum plant root structure that minimizes a single root’s hydraulic resistance is also studied in this work with the constraint of prescribed root volume. Hydraulic resistances under the slender body approximation and without such a limitation are considered. It is found that for large stele-to-cortex permeability ratio, there exists an optimum root length-to-base-radius ratio that minimizes the hydraulic resistance. A remarkable feature of the optimum root structure is that the optimum dimensionless stele conductivity depends only on a single geometrical parameter, the stele-to-root base-radius ratio. Once the stele-to-root base-radius ratio and the stele-to-cortex permeability ratio are given, the optimum root length-to-radius ratio can be found. While these findings remain to be verified by experiments for real plant roots, they offer theoretical guidance for the design of bio-inspired structures that minimizes hydraulic resistance for fluid production from porous media.