Influence of external magnetic field on the flow field in molten semiconductor of Czochralski crystal growth —A numerical simulation

Numerical results show that an external magnetic field may influence significantly the flow pattern in the molten semiconductor of Czochralski crystal growth. The melt flow could be pronouncedly damped by a magnetic field with the intensity of several thousands Gauss, while the temperature field is affected only in a less extent by the magnetic field. The project is supported by the National Natural Foundation of China.     

Two-phase flow laden with spherical particles in a microcapillary

Solid–liquid two-phase flow in a finite Reynolds number range (2 < Re < 12), transporting neutrally-buoyant microspheres with diameters of 6, 10, and 16 μm through a 260-μm microcapillary, is investigated. A standard microparticle-tracking velocimetry (μ-PTV) that consists of a double-pulsed Nd:YAG laser, an epi-fluorescent microscope, and a cooled-CCD camera is used to examine the flow. The solid particles are visualized in view of their spatial distributions. We observe a strong radial migration of the particles across the flow streamlines at substantially small Re. The degree of particle migration is presented in terms of probability density function. Some applications based on this radial migration phenomena are discussed in conjunction with particle separation/concentration in microfluidic devices, where the spatial distribution of particles is of great importance. In doing so, we propose a particle-trajectory function to empirically construct the spatial distribution of solid particles, which is well correlated with our experimental data. It is believed that this function provides a simple method for estimating the spatial distribution of particles undergoing radial migration in solid–liquid two-phase flows.     

Channel flow of a liquid crystal polymer around an obstacle: Weld line structure and strain field

 We have studied by in situ microscopy the flow of a lyotropic liquid crystal polymer, hydroxypropylcellulose (HPC) in water, around an obstacle placed in a rectangular flow channel. The obstacle separates the flow into two parts which rejoin downstream of the obstacle, resulting in the formation of a `weld-line'. Measuring the velocity field in the vicinity of the weld-line beyond the obstacle, we find as expected a positive elongational strain (acceleration) along the weld (parallel to the flow direction). For an anisotropic (concentrated) HPC solution we observe in addition a significant shear strain in the weld-line region, there being an important velocity gradient perpendicular to the plane of the weld line. Isotropic (lower concentration) solutions of the same polymer demonstrate no visible weld line, a larger elongational strain rate near the obstacle, and no shear component of strain downstream of the obstacle. These results are similar to observations reported for fluids reinforced by macroscopic fibres. Polarised light observations of the anisotropic solution show that the strain field generates a generally increased degree of orientation of the liquid crytalline polymer near the weld (generally reduced crossed-polariser transmitted intensity when the polariser is parallel to the flow direction), however there is also a striking fine birefringent colour variation in the weld-line region, reminiscent of the structure observed at the channel side walls in rectangular channel flow (Haw and Navard 2000). The results show that the simple concept of weld-line structure as confined to an enhanced alignment along the weld due to elongational strain is incomplete; the two-dimensional shear strain field must also be taken into account for the anisotropic fluid. Received: 22 December 1999/Accepted: 4 January 2000     

Forces on a spherical particle in shear flow at intermediate Reynolds numbers

When particles are submerged in a shear flow, there are lateral (lift) forces on the particles, and these lateral forces affect the dispersion of the particles very much. Recent literature survey indicates that there are large discrepancies among the results from the previous numerical investigations on this subject. A small computational domain ranging between 20–30 sphere radii was used in all the previous numerical investigations. However, the result from the present study reveals that the value of lift coefficient strongly depends on the size of computational domain. To provide correct numerical data and physical interpretation for the forces on a spherical particle in linear shear flow, accurate numerical computations were performed for 5≤Re≤200 using a computational domain of 101 sphere radii.     

The asymptotic solution of particle growth in the convective undercooled melt driven by a biaxial straining flow

A dynamical system of particle growth in the convective undercooled melt driven by a biaxial straining flow is modeled. A uniformly valid asymptotic solution for the interface evolution in particle growth is obtained by means of the multiple variable expansion method. The analytical solution as a function of both azimuth angle and polar angle shows that the interface shape of particle growth in the biaxial straining flow is significantly deformed by the biaxial straining flow. The biaxial straining flow results in higher local growth rate near the surface where the flow comes in and leads to lower local growth rate near the surface where the flow goes out. Due to the difference in local growth rate, an initially spherical particle will evolve into a prolate barrellike shape in the biaxial straining flow.     

The vapour–liquid interface and stresses in dried bodies

The paper presents a contribution to modelling the problem of vapour–liquid interface receding into dried body and stresses induced by drying of capillary-porous bodies. A complex algorithm comprising the specific mechanisms of drying in the first and second periods of drying is constructed. It enables calculation and drawing of the body temperature and drying curves for the whole drying process and identification of the vapour–liquid interface receding into the body. The drying induced stresses caused by the receding vapour–liquid interface and the non-uniform distribution of moisture content and/or temperature are analyzed. Numerical calculations of the temperature and drying curves and the drying induced stresses are carried out for the example of a finite dimensional kaolin cylinder dried convectively.     

Dynamic melt flow of nanocomposites based on poly-ɛ-caprolactam

 The dynamic flow behavior of polyamide-6 (PA-6) and a nanocomposite (PNC) based on it was studied. The latter resin contained 2 wt% of organoclay. The two materials were blended in proportions of 0, 25, 50, 75, and 100 wt% PNC. The dynamic shear rheological properties of well-dried specimens were measured under N₂ at T=240 °C, frequency ω=0.1–100 rad/s, and strains γ=10 and 40%. At constant T, γ, and ω the time sweeps resulted in significant increases of the shear moduli. The γ and ω scans showed a complex rheological behavior of all clay-containing specimens. At γ=10% the linear viscoelasticity was observed for all compositions only at ω>1 rad/s, while at γ=40% only for 0 and 25 wt% of PNC. However, the effect was moderate, namely decreasing G′ and G′′ (at ω=6.28 rad/s; γ=50%) by 15 and 7.5%, respectively. For compositions containing >25 wt% PNC two types of non-linearity were detected. At ω≤ω_c=1.4 ± 0.2 rad/s yield stress provided evidence of a 3-D structure. At ω > ω_c, G′ and G′′ were sensitive to shear history – the effect was reversible. From the frequency scans at ω > ω_c the zero-shear relative viscosity vs concentration plot was constructed. The initial slope gave the intrinsic viscosity from which the aspect ratio of organoclay particles, p=287 ± 9 was calculated, in agreement with the value calculated from the reduced permeability data, p=286. Received: 24 May 2001 Accepted: 27 August 2001     

The effect of a transition layer between a fluid and a porous medium: shear flow in a channel

Flow in a three-layer channel is modeled analytically. The channel consists of a transition layer sandwiched between a porous medium and a fluid clear of solid material. Within the transition layer, the reciprocal of the permeability varies linearly across the channel. The Brinkman model is used for the momentum equations for the porous medium layer and the transition layer. The velocity profile is obtained in closed form in terms of Airy, exponential, and polynomial functions. The overall volume flux and boundary friction factors are calculated and compared with values obtained with a two-layer model employing the Beavers–Joseph condition at the interface between a Darcy porous medium and a clear fluid.     

Fluid–solid interaction finite element modeling of a kinetically driven growth instability in stressed solids

The kinetically driven growth instability in stressed solids has been a subject of recent investigation as there is an increasing interest in the effects of non-hydrostatic stresses on crystal growth processes. Recent experimental and modeling work using advanced numerical methods such as boundary element and level set methods have demonstrated that the effect of stress on the solid phase epitaxy (SPE) growth of crystalline silicon from the amorphous phase is responsible for the roughening of its amorphous–crystalline interface. Although our previous model (Phan et al., in Model Simul Mater Sci Eng, 9:309–325, 2001) has been able to explain the observed interfacial instability during the crystal growth of intrinsic silicon, it has not been very successful when extended to the SPE growth process of doped silicon. In an effort to identify the sources that may improve the accuracy and robustness of the previously proposed model, we present in this paper a new approach for modeling the crystal growth in stressed Si layers. The technique is based upon the coupling of a transition-state-theory-based model, a finite element model of the sequentially weak coupling analysis for fluid-solid interaction, and the marker particle method.     

Numerical simulation of polyhedral crystal growth based on a mathematical model arising from non–local thermomechanics

In this work we present some results of the numerical simulation of the growth of a crystal from its melt, taking into account faceting. The simulation is based on a numerical solution of a three–dimensional generalized Stefan problem. That problem arises from a non–local thermomechanical theory applied to a continuous system with an interface and embodies ideas from the dislocation theory of crystal growth. In the model, the crystal surface is an isotherm and the growth velocity of a crystal face depends on the velocities of the other faces and on the whole crystal configuration as well as on the temperature gradient. A front fixing formulation of the model is considered. This is a conservative form of the Isotherm Migration Method [6, 7, 8, 9, 10, 11] in spherical coordinates. The numerical solution is based on an explicit finite difference discretization of the resulting non–linear equations. We develop a theoretical analysis of the interface equations that drive the crystal face motion. Numerical results, showing evolution of complex crystals with configuration changing during the growth, are in accord with experimental results. Furthermore, numerical experiments offer useful information on the influence of certain parameters in the model on the growth process. Received: March 21, 1996     

The effect of an acoustic field on a secondary convective flow in a layer

The effect of a traveling sonic wave on a convective flow in a horizontal layer with a fixed linear temperature distribution on the boundaries is investigated. Convective rolls with axes parallel to the basic flow (lengthwise rolls) are considered. On the basis of a weakly nonlinear analysis, it is shown that the lengthwise rolls appear smoothly and the regular flows are stable near the stability threshold. A direct numerical simulation is performed. Secondary near-critical flow regimes and regimes corresponding to finite supercriticalities are investigated.     

The effect of magnetic field on two-phase liquid metal flow

In this paper, the basic equations of two-phase liquid metal flow in a magnetic field are derived, and specifically, two-phase liquid metal MHD flow in a rectangular channel is studied, and the expressions of velocity distribution of liquid and gas phases and the ratioK ₀ of the pressure drop in two-phase MHD flow to that in single-phase are derived. Results of calculation show that the ratioK ₀ is smaller than unity and decreases with increasing void fraction and Hartmann number because the effective electrical conductivity in the two-phase case decreases. The Project is supported by the National Natural Science Foundation of China.     

Simultaneous measurement of transient stress and flow birefringence in one-sided compression (biaxial extension) of a polymer melt

Summary Investigation of time dependent behaviour of a polystyrene melt is carried out with the aid of a new apparatus for biaxial extension. Use is made of the method of two impinging fluid streams guided by lubricated trumpet shaped metal walls. The flow birefringence is measured in the plane of symmetry and, at the same time, the force is measured which tends to separate the trumpets. The linear stress-optical relation turns out to be valid in this new flow geometry. An accurate value for the stress-optical coefficient can be determined from the relaxation experiments. The stress build-up as calculated from the optical measurements, is compared with the pertinent result of the theory of linear viscoelasticity. For the desired interconversion of dynamic moduli use is made of the approximation by Schwarzl and Struik. The steady state measurements are checked by the results of the non-linear model of Acierno et al.With 16 figures and 2 tables     

The influence of blending polystyrenes of narrow molecular weight distribution on melt creep flow and creep recovery in elongation

Creep and creep recovery experiments in elongation were performed with melts of anionically polymerized polystyrenes (PS) and with their blends at a temperature of 150 °C. For stresses ₀ < 10 000 N/m² the samples with narrow molecular weight distribution show linear viscoelastic behavior up to the maximum Hencky strain = 3.5, achievable in a newly developed elongational rheometer for polymer melts. The compliances,D (t), of the blends are linear-viscoelastic only up to a strain limit _L . For strains beyond _L the compliance of each blend depends on the stress ₀. For a series of binary blends, prepared from the same components of narrow MWD, the linear-viscoelastic limit _L seems to be independent of the mixing ratio and stress. _L seems to be a function only of the molecular weights of the original components, the blends investigated were made from.Paper presented at the Annual Conference of the German Society of Rheology at Ulm, March 7–10, 1983.     

Effect of the melt flow direction on the treeing process in polymeric insulation

This paper presents the results of a study of the effect of the residual mechanical stress formed in solid polymers at the stage of production on the initiation and growth of an electrical tree. It is shown that the time to tree initiation and the time to breakdown of polycarbonate samples can be determined from the results of investigation of treeing parameters. __________ Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 50, No. 1, pp. 85–94, January–February, 2009.     

A molecular dynamics study of the stress–optical behavior of a linear short-chain polyethylene melt under shear

In this study, we present details of the stress–optical behavior of a linear polyethylene melt under shear using a realistic potential model. We demonstrate the existence of the critical shear stress, above which the stress–optical rule (SOR) begins to be invalid. The critical shear stress of the SOR of this melt turns out to be 5.5 MPa, which is fairly higher than 3.2 MPa at which shear thinning starts, indicating that the SOR is valid up to a point well beyond the incipient point of shear thinning. Furthermore, contrary to conventional wisdom, the breakdown of the SOR turns out not to be correlated with the saturation of chain extension and orientation: It occurs at shear rates well before maximum chain extension is obtained. In addition to the stress and birefringence tensors, we also compare two important coarse-grained second-rank tensors, the conformation and orientation tensors. The birefringence, conformation, and orientation tensors display nonlinear relationships to each other at high values of the shear stress, and the deviation from linearity begins at approximately the critical shear stress for breakdown of the SOR.     

A finite element method for analysis of fluid flow,heat transfer and free interfaces in Czochralski crystal growth

A finite element algorithm is presented for simultaneous calculation of the steady state, axisymmetric flows and the crystal, melt/crystal and melt/ambient interface shapes in the Czochralski technique for crystal growth from the melt. The analysis is based on mixed Lagrangian finite element approximations to the velocity, temperature and pressure fields and isoparametric approximations to the interface shape. Galerkin's method is used to reduce the problem to a non-linear algebraic set, which is solved by Newton's method. Sample solutions are reported for the thermophysical properties appropriate for silicon, a low-Prandtl-number semiconductor, and for GGG, a high–Prandtl–number oxide material. The algorithm is capable of computing solutions for both materials at realistic values of the Grashof number, and the calculations are convergent with mesh refinement. Flow transitions and interface shapes are calculated as a function of increasing flow intensity and compared for the two material systems. The flow pattern near the melt/gas/crystal tri-junction has the asymptotic form predicted by an inertialess analysis assuming the meniscus and solidification interfaces are fixed.     

Efficient approaches of determining the motion of a spherical particle in a swirling fluid flow using weighted residual methods

The motion of a spherical particle released in a swirling fluid flow is studied employing the least-squares method and method of moments. The governing equations are obtained and solved employing the two methods. The accuracy of the results is examined against the results of a fourth-order Runge–Kutta numerical method. The effects of various parameters, namely the initial radius, initial radial velocity, initial angular velocity, and drag-to-inertia ratio, on the non-dimensional velocity profiles and particle position distribution are considered. The results show that the radial velocity increases over time while the angular velocity decreases, and that an increase in the initial radial velocity increases the particle radial distance and angular velocity but decreases the radial velocity profile.     

Numerical simulation of laminar natural convection in a laterally heated vertical cylindrical enclosure: application to crystal growth

Laminar natural convection has been studied in a laterally heated vertical cylindrical enclosure with a free insulated surface and a centrally located constant temperature wall at the top. These conditions are a simplification of the conditions existing in a Czochralski crystal pulling system. The laminar, axisymmetric flow of a Newtonian, constant physical properties fluid under Boussinesq’s approximation has been considered. Governing equations in primitive variable form are solved numerically by control volume method. SIMPLE algorithm due to Patankar has been used for the numerical simulation. The effects of the constant wall heat flux boundary condition at the side wall have been investigated whereas the bottom wall is considered to be insulated. Streamlines and isotherms are presented for various Rayleigh numbers and Prandtl numbers. Heat flux vectors through the melt are plotted for selected cases. The axial velocity and temperature variations at different horizontal sections of the crucible have been presented graphically to explain the transport processes inside the crucible. It has been observed that in case of low Pr and high Ra, flow separation occurs at the vertical wall of the crucible which leads to an oscillatory flow as Ra increases. The investigation has been extended to the oscillatory regime of flow in the zone of supercritical Rayleigh numbers and some unsteady results are also presented. Finally a heat transfer correlation has been developed for steady-state case.     

Mathematical expression of pressure gradient in the flow of spherical capsules less dense than water

This study yielded a mathematical expression to calculate the pressure gradient (ΔP/L)_m of the flow of a spherical capsule train. An experimental investigation was carried out to determine pressure drops of two-phase mixture flow of spherical ice capsules and water inside the pipelines of cooling systems. Instead of ice capsules, spherical capsules made of polypropylene material whose density (870 kg/m³) is similar to that of ice were used in the experiments. Flow behavior of the spherical capsules, 0.08 m outer diameter, was observed in the measuring section inside plexiglass pipes, 0.1 m inner diameter (ID) and 6 m in length; pressure drops were measured on the 4 m section. The investigation was carried out in the 1.2 × 10⁴ < Re < 1.5 × 10⁵ range and under transport concentration (C_tr) by 5–30%. Dimensionless numbers of the physical event were found out by conducting a dimensional analysis, so that mixture density was expressed in terms of specific gravity and in situ concentration. After arriving at certain conclusions based on the relevant experimental findings and observations, empirical and mathematical models which can be used for calculation of the pressure gradient were developed. Comparison of the mathematical model with the experimental findings revealed that pressure drop values deviated by 2.7% on average for 2.5 × 10⁴ < Re < 1.5 × 10⁵.