Thermal and gas flow characterization of a fluxless Si solder bonding oven

In this paper the technology of the “Linn” type Si fluxless solder bonding oven and the thermal and gas flow characterization of the oven are discussed. This oven is used for fixing silicon chips on metal substrates with high temperature solder bonding process. The solder is applied in a foil form which is placed between the Si chip and the metal substrate. This does not contain any flux, therefore a reducing agent has to be applied to avoid the oxidation of the joints during the soldering process. In this technology the reducing agent is the forming gas which is a mixture of 10 vol.% H₂ and 90 vol.% N₂. The key factors of this soldering process was studied; the suitable temperature (350-370 °C for 13-15 min) and the adequate H₂ concentration (8-10 vol.%). A detailed 3D gas flow model of the Linn oven was prepared which is based on the finite volume model (FVM) method. The gas flow circumstances using the basic and a hypothetic oven setting were compared by simulations applied the ANSYS-FLUENT system. The gas flow model was verified by the measurements of the temperature, the H₂ concentration and the pressure inside the oven. Furthermore the heating ability of the oven under full load was characterized by the change of the heating temperature and the time coefficient of the heating.     

Thermal analyses of LiCoO2 lithium-ion battery during oven tests

A three dimensional thermal abuse model for graphite/LiPF₆/LiCoO₂ batteries is established particularly for oven tests. To investigate the influence of heat release condition and oven temperature on battery thermal behaviors, we perform a series of simulations with respect to a unit cell during oven thermal abuses of various oven temperatures and under various heat release conditions. Simulation results enable detailed analyses to thermal behaviors of batteries. It is found that during oven thermal abuse processes that do not get into thermal runaway, the negative electrode is the maximum heat generation rate zone; during oven thermal abuse processes that do get into thermal runaway, the positive electrode is the maximum heat generation rate zone. The positive-solvent reaction is found to be the major heat generation source causing thermal runaway. It is also found that the heat release condition and the oven temperature are combined to dictate thermal behaviors of the battery. The critical oven temperature that causes thermal runaway rises if the heat release condition is better and the critical heat release coefficient that can effectively restrain the occurrence of thermal runaway increases with the increase of oven temperature.     

Self-similar flow of a mixture of a non-ideal gas and small solid particles behind a shock wave in presence of heat conduction, radiation heat flux and a gravitational field

Similarity solutions are obtained for one-dimensional unsteady flow of a dusty gas behind a spherical shock wave with heat conduction and radiation heat flux under a gravitational field of heavy nucleus at the centre (Roche model). The dusty gas is assumed to be a mixture of small solid particles and a non-ideal gas. The equilibrium flow conditions are assumed to be maintained, and the heat conduction is expressed in terms of Fourier’s law and the radiation is considered to be of the diffusion type for an optically thick grey gas model. The thermal conductivity K and the absorption coefficient α _R are assumed to vary with temperature and density. In order to obtain similarity solutions the density of the undisturbed medium is assumed to be constant. The effects of an increase in the value of the parameter of non-idealness of the gas in the mixture $\bar{b}$ , the mass concentration of the solid particles in the mixture K _p , the ratio of the density of the solid particles to the initial density of the gas G ₁ and the variation of the heat transfer parameters Γ _R and Γ _c are obtained.     

Columnar heat transport via advection induced by inertial waves

Inertial waves are oscillations in a rotating fluid that arise due to the restoring action of the Coriolis force. Low-frequency inertial waves are known to create columnar flow structures inrapidly rotating systems. Columnar heat transport away from the equator has been observed in some strongly forced, rapidly-rotating geodynamo simulations of the Earth’s core. In this study, we investigate the mechanism governing this heat transport by performing direct numerical simulations of model problems comprising buoyant blobs under rapid rotation in a periodic box. We consider a wide range of Rossby numbers (Ro), the ratio of advection to Coriolis force, and Peclet numbers (Pe), the ratio of thermal advection to thermal diffusion. Columnar flow structures, that comprise inertial wave packets, are observed to emerge from the buoyant regions and travel towards the box boundary. We find that the columnar heat transport occurs by advection governed by the local Pe (for instance, a larger vertical elongation in the blob is observed for larger Pe at the same Ro). The magnitude of the advection velocity is determined by the balance between the buoyancy and Coriolis forces. Moreover, the direction of advection is determined by the direction of the wave-induced flow in the columns above and below the blob. Our results suggest that the local Pe could be important for the columnar heat transport in strongly forced dynamo simulations.     

Numerical investigation of flow and heat transfer in a gas-droplet separated turbulent stream using the Reynolds stress transfer model

The results of the numerical modeling of flow structure, turbulence, and heat transfer in a gas-droplet stream after sudden tube expansion on the basis of the Eulerian approach are presented. The gas phase turbulence was modeled using the Reynolds stress transfer model modified to allow for the presence of particles. The results are compared with those obtained using the two-equation k-ε model. The latter results overestimate the heat transfer in the separation flow as compared with the Reynolds stress transfer model. The heat transfer is shown to considerably increase, when evaporating droplets are incorporated in the separation flow (by a factor of more than 1.5 compared with the case of a single-phase flow at a small mass concentration of the droplets M _L1 ≤ 0.05). The addition of the disperse phase in the turbulent gas flow leads a slight increase in the recirculation zone length. Good agreement with the experimental data indicates the adequacy of the numerical model developed.     

Solution to radiative transfer equation in a 3-D rectangular enclosure due to discontinuous heat flow divergence

In this paper a new model and computer code is presented by considering singular and discontinuous heat flow divergence. A hybrid model including Smith’s WSGG model and Coppale and Vervish’s model is used for calculating gas radiative properties. Energy equation is solved simultaneously to reach temperature field which specify gas radiative properties. S ₈ order of discrete ordinate method is used to solve RTE. It is assumed that walls of enclosure are gray, diffuse and opaque with specified temperature. Boundary conditions are corrected in each iteration that change temperature field.     

The Effect of Droplets Evaporation on Turbulence Modification and Heat Transfer Enhancement in a Two-Phase Mist Flow Downstream of a Pipe Sudden Expansion

Turbulent droplet-laden flow downstream of a sudden pipe expansion is numerically studied using an Eulerian two-fluid model. The model is used to investigate the effect of droplet evaporation on the particle dispersion and on the gas phase turbulence modification. Turbulence suppression in the case of evaporating droplets is hardly observed near the wall, and the level of turbulence tends to the corresponding value for the single-phase flow regime. In the flow core, where evaporation is insignificant, a decrease in the level of gas turbulence (to 20 % as compared to a single-phase flow) can be observed. The maximal effect of droplet evaporation is obtained in the wall region of the tube. A considerable increase in the maximal value of heat exchange on adding the evaporating droplets to the separated flow is shown (more than 1.5-fold as compared to the single-phase flow at a small value of droplet mass concentration of M _L1≤ 0.05). The addition of the solid non-evaporating particles causes a slight increase in the maximum value of heat transfer in the case of small particles and a decrease in heat transfer in the case of large particles.     

Slip effects on unsteady stagnation-point flow and heat transfer over a shrinking sheet

This paper investigates the unsteady boundary layer stagnation-point flow and heat transfer over a linearly shrinking sheet in the presence of velocity and thermal slips. Similarity solutions for the transformed governing equations are obtained and the reduced equations are then solved numerically using fourth order Runge-Kutta method with shooting technique. The numerical results show that multiple solutions exist for certain range of the ratio of shrinking velocity to the free stream velocity (i.e., α) which again depend on the unsteadiness parameter β and the velocity slip parameter (i.e., δ). An enhancement of the velocity slip parameter δ causes more increment in the existence range of similarity solution. Fluid velocity at a point increases increases with the increase in the value of the velocity slip parameter δ, resulting in a decrease in the temperature field. The effects of the velocity and thermal slip parameters, unsteadiness parameter (β) and the velocity ratio parameter (α) on the velocity and temperature distributions are computed, analyzed and discussed. The reported results are in good agreement with the available published results in the literature.     

Numerical analysis of turbulent convection heat transfer from an array of perforated fins

Numerical investigation is made for three-dimensional fluid flow and convective heat transfer from an array of solid and perforated fins that are mounted on a flat plate. Incompressible air as working fluid is modeled using Navier–Stokes equations and RNG based k ? ? turbulent model is used to predict turbulent flow parameters. Temperature field inside the fins is obtained by solving Fourier’s conduction equation. The conjugate differential equations for both solid and gas phase are solved simultaneously by finite volume procedure using SIMPLE algorithm. Perforations such as small channels with square cross section are arranged streamwise along the fin’s length and their numbers varied from 1 to 3. Flow and heat transfer characteristics are presented for Reynolds numbers from 2 × 10⁴ to 4 × 10⁴ based on the fin length and Prandtl number is taken Pr = 0.71. Numerical computations are validated with experimental studies of the previous investigators and good agreements were observed. Results show that fins with longitudinal pores, have remarkable heat transfer enhancement in addition to the considerable reduction in weight by comparison with solid fins.     

Experimental study of augmented heat transfer and friction in solar air heater with different orientations of W-Rib roughness

Artificial roughness in the form of ribs is a convenient method for enhancing thermal performance of solar air heaters. This paper presents the experimental investigation of heat transfer and friction factor characteristics of a rectangular duct roughened with W-shaped ribs arranged at an inclination with respect to the flow direction on its underside on one broad wall. W ribs have been tested both pointing in downstream W-down and upstream W-up to the flow. The range of parameters for this study has been decided on the basis of practical considerations of the system and operating conditions. The duct has a width to height ratio (W/H) of 8.0, relative roughness pitch (p/e) of 10, relative roughness height (e/D_h) of 0.03375 and angle of attack of flow (α) of 30-75°. The air flow rate corresponds to Reynolds number between 2300-14,000. The heat transfer and friction factor results have been compared with those for smooth duct under similar flow and thermal boundary condition and thermo-hydraulic performance has been investigated. Thermo-hydraulic performance comparison for different angle of attack of flow shows that W-down arrangement with angle of attack of flow as 60° gives best thermo-hydraulic performance. In addition heat transfer and friction factor correlations have been developed.     

Numerical simulation of a supersonic gas–solid flow over a blunt body: The role of inter-particle collisions and two-way coupling effects

A supersonic dusty gas flow over a blunt body is considered. The mathematical model of the two-phase gas–particle flow takes into account the inter-particle collisions and the two-way coupling effects. The carrier gas is treated as a continuum, the averaged flow field of which is described by the complete Navier–Stokes equations with additional source terms modeling the reverse action of the dispersed phase. The dispersed phase is treated as a discrete set of solid particles, and its behavior is described by a kinetic Boltzmann-type equation. Particles impinging on the body surface are assumed to bounce from it. Numerical analysis is carried out for the cross-wise flow over a cylinder. The method of computational simulation represents a combination of a CFD-method for the carrier gas and a Monte Carlo method for the “gas” of particles. The dependence of the fine flow structure of the continuous and dispersed phases upon the free stream particle volume fraction α_p∞ and the particle radius r_p is investigated, particularly in the shock layer and in the boundary layer at the body surface. The particle volume fraction α_p∞ is varied from a negligibly low value to the value α_p∞ = 3 × 10⁵ at which inter-particle collisions and two-way coupling effects are simultaneously essential. Particular attention has been given to the particles of radii close to the critical value r_p1, because in this range of particle size the behavior of the particles and their effect on the carrier gas flow are not yet completely understood. An estimate of the turbulent kinetic energy produced by the particles in the shock layer is obtained.     

A method for calculating intense injection from surfaces of blunt bodies entering planetary atmospheres at hypersonic velocities

Flow past blunt bodies entering planetary atmospheres at hypersonic velocities is studied. A method for calculating the flowfield near the body nose is developed which allows for radiative heat transfer in the P ₁ approximation of the spherical harmonics method but does not take gas viscosity and heat conduction into account. The solution is constructed on the basis of a two-layer flow model, with account for intense injection of ablation products from the body nose due to radiative heat fluxes from the shock layer. The advantages of the method are that the multi-dimensional character of the radiation field is taken into account and the general problem of radiation gasdynamics is solved on the basis of a unified algorithm. The flow past a spherical segment and a spherically-blunted cone re-entering the Earth’s atmosphere at a velocity of 20 km/s and an entry angle of ?10° is calculated.     

Conjugate natural convection heat transfer between two fluids separated by a horizontal wall: steady-state analysis

The conjugate heat transfer across a thin horizontal wall separating two fluids at different temperatures is investigated both numerically and asymptotically. The solution for large Rayleigh numbers is shown to depend on two nondimensional parameters;α/ε ², withα being the ratio of the thermal resistance of the boundary layer in the hot medium to the thermal resistance of the wall andε the aspect ratio of the plate, andβ, the ratio of the thermal resistances of the boundary layers in the two media. The overall Nusselt number is an increasing function ofα/ε ² taking a finite maximum value forα/ε ² → ∞ and tending to zero forα/ε ² → 0.     

Heat transfer during gas hydrate formation in gas-liquid slug flow

A model of heat transfer during gas hydrate formation at a gas-liquid interface in gas-liquid slug flow is suggested. Under the assumption of perfect mixing in liquid plugs, the recurrent relations for temperature in then-th liquid plug and heat and mass fluxes from then-th gas slug are derived. Total mass and heat fluxes in gas-liquid slug flow during gas hydrate formation are determined.     

Stability of dual solutions in stagnation-point flow and heat transfer over a porous shrinking sheet with thermal radiation

An analysis is carried out to study the steady two-dimensional stagnation-point flow and heat transfer of an incompressible viscous fluid over a porous shrinking sheet in the presence of thermal radiation. A set of similarity transformations reduce the boundary layer equations to a set of non-linear ordinary differential equations which are solved numerically using fourth order Runge-Kutta method with shooting technique. The analysis of the result obtained shows that as the porosity parameter β increases, the range of region of existence of similarity solution increases. It is also observed that multiple solutions exist for a certain range of the ratio of the shrinking velocity to the free stream velocity (i.e., α) which again depends on β. We then discuss the stability of the unsteady solutions about each steady solution, showing that one steady state solution corresponds to a stable solution whereas the other corresponds to an unstable solution. The stable solution corresponds to the physically relevant solution. Further we obtain numerical results for each solution, which enable us to discuss the features of the respective solutions.     

Nanofluids thermal behavior analysis using a new dispersion model along with single-phase

A numerical study has been performed to analyze nanofluids convective heat transfer. Laminar α-Al₂O₃-water nanofluid flows in an entrance region of a horizontal circular tube with constant surface temperature. Numerical analysis has been carried out using two different single-phase models (homogenous and dispersion) and two-phase models (Eulerian–Lagrangian and mixture). A new model is developed to consider the nanoparticles dispersion. The transport equations for the tube with constant surface temperature were solved numerically using a control volume approach. The effects of nanoparticles volume fraction (0.5, 1 %) and Reynolds number (650 ≤ Re ≤ 2300) on nanofluid convective heat transfer coefficient were studied. The results are compared with the experimental data and it is shown that the homogenous single-phase model is underestimated and the mixture model is overestimated. Although the Eulerian–Lagrangian model gives a reasonable prediction for the thermal behavior of nanofluids, the dispersion single-phase model gives more accurate prediction despite its simplicity.     

Pressure-sensitive ductile layers – I. Modeling the growth of extensive damage

Polymeric adhesives sandwiched between two elastic substrates are commonly found in multi-layers and IC packages. The non-elastic deformation and flow stress of such adhesive joints are highly pressure-sensitive. In this work, we study the effects of pressure-sensitivity, α, and plastic dilatancy, β, on void growth and coalescence ahead of a crack in ductile adhesive joints. To this end, a single layer of discrete voids is placed ahead of the crack in a pressure-sensitive dilatant adhesive sandwiched between two elastic substrates. The adhesive joint is subjected to small-scale yielding conditions. Using an associated flow rule (α = β), we show that pressure-sensitivity not only intensifies damage levels but also increases its spatial extent several fold. The damage level as well as its spatial extent is found to be even greater when a non-associated flow rule (β < α) is deployed. A reduction in the damage process zone’s thickness further increases the voiding activity in the adhesive, thereby resulting in brittle-like failure. This work also examines the fracture toughness trends using a material failure criterion for crack growth.     

MHD flow and heat transfer of a UCM fluid over a stretching surface with variable thermophysical properties

In this paper we investigate the effects of temperature-dependent viscosity, thermal conductivity and internal heat generation/absorption on the MHD flow and heat transfer of a non-Newtonian UCM fluid over a stretching sheet. The governing partial differential equations are first transformed into coupled non-linear ordinary differential equation using a similarity transformation. The resulting intricate coupled non-linear boundary value problem is solved numerically by a second order finite difference scheme known as Keller-Box method for various values of the pertinent parameters. Numerical computations are performed for two different cases namely, zero and non-zero values of the fluid viscosity parameter. That is, 1/?? _r ??0 and 1/?? _r ??0 to get the effects of the magnetic field and the Maxwell parameter on the velocity and temperature fields, for several physical situations. Comparisons with previously published works are presented as special cases. Numerical results for the skin-friction co-efficient and the Nusselt number with changes in the Maxwell parameter and the fluid viscosity parameter are tabulated for different values of the pertinent parameters. The results obtained for the flow characteristics reveal many interesting behaviors that warrant further study on the non-Newtonian fluid phenomena, especially the UCM fluid phenomena. Maxwell fluid reduces the wall-shear stress.     

Modeling fluid and heat transport in the reactive, porous bed of downdraft (biomass) gasifier

A fluid flow and heat transfer model has been developed for the reactive, porous bed of the biomass gasifier to simulate pressure drop, temperature profile in the bed and flow rates. The conservation equations, momentum equation and energy equation are used to describe fluid and heat transport in porous gasifier bed. The model accounted for drag at wall, and the effect of radial as well as axial variation in bed porosity to predict pressure drop in bed. Heat transfer has been modeled using effective thermal conductivity approach. Model predictions are validated against the experiments, while effective thermal conductivity values are tested qualitatively using models available in literature. Parametric analysis has been carried out to investigate the effect of various parameters on bed temperature profile and pressure drop through the gasifier. The temperature profile is found to be very sensitive to gas flow rate, and heat generation in oxidation zone, while high bed temperature, gas flow rate and the reduction in feedstock particle size are found to cause a marked increase in pressure drop through the gasifier. The temperatures of the down stream zones are more sensitive to any change in heat generation in the bed as compared to upstream zone. Author recommends that the size of preheating zone may be extended up to pyrolysis zone in order to enhance preheating of input air, while thermal insulation should not be less than 15 cm.     

热喷干扰气体模型对飞行器气动特性影响分析

针对不同气体模型对高超声速飞行器喷流反作用控制系统(RCS)热喷干扰流场模拟的计算效率和准确性问题, 基于喷流燃气物理化学模型, 通过数值求解含化学反应源项的三维N-S方程, 建立了飞行器RCS热喷干扰流场数值模拟方法, 分别采用化学反应流、反应冻结流、二元异质流以及空气喷流四种气体模型开展了典型外形热喷干扰流场的数值模拟, 研究了不同气体模型对热喷干扰流场结构、飞行器气动力热特性的影响, 分析了不同马赫数、飞行高度下的变化规律. 研究表明: 化学反应流模型计算精度较高, 计算与风洞试验数据的吻合程度优于其他三种简化模型; 在本文的低空条件下, 采用简化模型进行热喷干扰流场数值模拟, 会低估分离区大小, 使飞行器气动力特性预测出现偏差, 同时也会低估表面热环境, 对防热系统设计不利, 随着马赫数增加, 简化模型对气动力热特性预估的误差进一步增大, 同时不同简化模型之间的差异也进一步增大; 飞行高度较高时, 模型之间的差异减小, 此时可采用简化模型进行计算以提高计算效率. 本文的研究结果可为飞行器热喷干扰流场数值模拟及喷流反作用控制系统设计提供参考.