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Kinetics of Molten Metal Capillary Flow in Non- Reactive and Reactive Systems

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Kinetics of Molten Metal Capillary Flow in Non- Reactive and Reactive Systems University of Kentucky UKnowledge Theses and Dissertations--Mechanical Engineering Mechanical Engineering 2016 KINETICS OF MOLTEN METAL CAPILLARY FLOW IN NON- REACTIVE AND REACTIVE SYSTEMS Hai Fu University of Kentucky, [email protected] Digital Object Identifier: http://dx.doi.org/10.13023/ETD.2016.163 Right click to open a feedback form in a new tab to let us know how this document benefits ou.y Recommended Citation Fu, Hai, "KINETICS OF MOLTEN METAL CAPILLARY FLOW IN NON-REACTIVE AND REACTIVE SYSTEMS" (2016). Theses and Dissertations--Mechanical Engineering. 79. https://uknowledge.uky.edu/me_etds/79 This Doctoral Dissertation is brought to you for free and open access by the Mechanical Engineering at UKnowledge. It has been accepted for inclusion in Theses and Dissertations--Mechanical Engineering by an authorized administrator of UKnowledge. For more information, please contact [email protected]. STUDENT AGREEMENT: I represent that my thesis or dissertation and abstract are my original work. Proper attribution has been given to all outside sources. I understand that I am solely responsible for obtaining any needed copyright permissions. I have obtained needed written permission statement(s) from the owner(s) of each third-party copyrighted matter to be included in my work, allowing electronic distribution (if such use is not permitted by the fair use doctrine) which will be submitted to UKnowledge as Additional File. I hereby grant to The University of Kentucky and its agents the irrevocable, non-exclusive, and royalty-free license to archive and make accessible my work in whole or in part in all forms of media, now or hereafter known. I agree that the document mentioned above may be made available immediately for worldwide access unless an embargo applies. I retain all other ownership rights to the copyright of my work. I also retain the right to use in future works (such as articles or books) all or part of my work. I understand that I am free to register the copyright to my work. REVIEW, APPROVAL AND ACCEPTANCE The document mentioned above has been reviewed and accepted by the student’s advisor, on behalf of the advisory committee, and by the Director of Graduate Studies (DGS), on behalf of the program; we verify that this is the final, approved version of the student’s thesis including all changes required by the advisory committee. The undersigned agree to abide by the statements above. Hai Fu, Student Dr. Dusan P. Sekulic, Major Professor Dr. Haluk E. Karaca, Director of Graduate Studies KINETICS OF MOLTEN METAL CAPILLARY FLOW IN NON-REACTIVE AND REACTIVE SYSTEMS DISSERTATION A dissertation submitted in partial fulfillment of the requirements for the degree of Doctor of Philosophy in the College of Engineering at the University of Kentucky By Hai Fu Lexington, Kentucky Director: Dr. Dusan P. Sekulic, Professor of University of Kentucky Co-Director: Dr. Kozo Saito, Professor of University of Kentucky Lexington, Kentucky 2016 Copyright © Hai Fu 2016 ABSTRACT OF DISSERTATION KINETICS OF MOLTEN METAL CAPILLARY FLOW IN NON-REACTIVE AND REACTIVE SYSTEMS Wetting and spreading of liquid systems on solid substrates under transient conditions, driven by surface tension and viscous forces along with the interface interactions (e.g., a substrate dissolution or diffusion and/or chemical reaction) is a complex problem, still waiting to be fully understood. In this study we have performed an extensive experimental investigation of liquid aluminum alloy spreading over aluminum substrate along with corroboration with theoretical modeling, performed in separate but coordinate study. Wetting and spreading to be considered take place during a transient formation of the free liquid surface in both sessile drop and wedge-tee mating surfaces’ configurations. The AA3003 is used as a substrate and a novel self-fluxing material called TrilliumTM is considered as the filler metal. In addition, benchmark, non-reactive cases of spreading of water and silicon oil over quartz glass are considered. The study is performed experimentally by a high temperature optical dynamic contact angle measuring system and a standard and high speed visible light camera, as well as with infra read imaging. Benchmark tests of non-reactive systems are conducted under ambient environment’s conditions. Molten metal experiment series featured aluminum and silicone alloys under controlled atmosphere at elevated temperatures. The chamber atmosphere is maintained by the ultra-high purity nitrogen gas purge process with the temperature monitored in real time in situ. Different configurations of the wedge-tee joints are designed to explore different parameters impacting the kinetics of the triple line movement process. Different power law relationships are identified, supporting subsequent theoretical analysis and simulation. Under ambient temperature conditions, the non-reactive liquid wetting and spreading experiments (water and oil systems) were studied to verify the equilibrium triple line location relationships. The kinetics relationship between the dynamic contact angle and the triple line location is identified. Additional simulation and theoretical analysis of the triple line movement is conducted using the commercial computer software platform Comsol in a collaboration with a team from Washington State University within the NSF sponsored Grant #1235759 and # 1234581. The experimental work conducted here has been complemented by a verification of the Comsol phase-field modeling. Both segments of work (experimental and numerical) are parts of the collaborative NSF sponsored project involving the University of Kentucky and Washington State University. The phase field modeling used in this work was developed at the Washington State University and data are corroborated with experimental results obtained within the scope of this Thesis. KEYWORDS: Kinetics, Wetting and Spreading, Wedge-tee, TrilliumTM, Model Hai Fu Apr. 15th, 2016 KINETICS OF MOLTEN METAL CAPILLARY FLOW IN NON-REACTIVE AND REACTIVE SYSTEMS By Hai Fu Dr. Dusan P. Sekulic Director of Dissertation Dr. Kozo Saito Co-Director of Dissertation Dr.Haluk E. Karaca Director of Graduate Studies Apr. 15th, 2016 DEDICATION DEDICATED TO MY PARENTS FOR SUPPORTING ME OVER THE YEARS UNCONDITIONALLY AND KENNETH TUBAUGH FOR STANDING BY MY SIDE THROUGH IT ALL ACKNOWLEDGEMENTS This dissertation and my PhD research work over the years were funded by multiple NSF projects. I want to thank my advisor Professor Dusan P. Sekulic for his generosity, resourceful insight and most of all, his kind support and encouragement. I would never have been able to finish my dissertation without his guidance and help. My deepest gratitude goes to Professor Dusan P. Sekulic for accepting me as his student when time was the hardest for me. The excellent research atmosphere in the ISM Brazing, Soldering and Heat Exchangers Research Laboratory will always be one of the best memories in my life. I would like to thank my committee members, Dr. Kozo Saito, Dr. Y-T Cheng, Dr. Tianxiang Li and Dr. John Young, for their guidance and time during the defense process. Special thanks goes to Dr. Michael Winter for being willing for participating in my final defense committee at the last moment. Many thanks to Dr. Mikhail Krivilev, Dr. Sinisa Mesarovic and Mohammad Dehsara for the continuous cooperation research in the NSF project. And many thanks to Dr. Fazleena Badurdeen, Dr. Robert Gregory, Dr. Margaret Schroder, Dr. Leslie Vincent, Dr. Gregory Luhan and Adam Brown for making the NSF funded course work a wonderful experience. Thanks to Dr. Doug Hawksworth and Daniel Busbaher for their support in the research work. Thanks to Dr. Haluk E. Karaca and his students Sayed M. Saghaian and Ali Turabi for allowing me to use his lab facilities to conduct several experiments. Thanks to Mechanical Engineering Department staff members, Charles Arvin, Heather-Michele Adkins, Peter Hayman and Steven Adkins, for their help and support during my PhD study. Finally, I would like to thank my parents for being my parents with love and support no matter what. And I would like to thank Kenneth Tubaugh for being there for me through thick and thin. iii TABLE OF CONTENTS ACKNOWLEDGEMENTS ............................................................................................................ iii LIST OF TABLES ......................................................................................................................... vii LIST OF FIGURES ...................................................................................................................... viii CHAPTER 1: INTRODUCTION ................................................................................................... 1 1.1 Background Fundamentals ..................................................................................................... 1 1.2 Scope of the research ............................................................................................................. 4 1.3 Organization of the dissertation ............................................................................................. 5 CHAPTER 2: LITERATURE REVIEW ........................................................................................ 7 2.1 Overview ................................................................................................................................ 7 2.2 Wetting and spreading ..........................................................................................................
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