As companies strive to develop artefacts intended for services instead of traditional sell-off, new challenges in the product development process arise to promote continuous improvement and increasing market profits. This creates a focus on product life-cycle components as companies then make life-cycle commitments, where they are responsible for the function availability during the extent of the life-cycle, i.e. functional products. One of these life-cycle components is manufacturing; therefore, companies search for new approaches of success during manufacturability evaluation already in engineering design. Efforts have been done to support early engineering design, as this phase sets constraints and opportunities for manufacturing. These efforts have turned into design for manufacturing methods and guidelines. A further step to improve the life-cycle focus during early engineering design is to reuse results and use experience from earlier projects. However, because results and experiences created during project work are often not documented for reuse, only remembered by some people, there is a need for design support. Knowledge engineering (KE) is a methodology for creating knowledge-based systems, e.g. systems that enable reuse of earlier results and make available both explicit and tacit corporate knowledge, enabling the automated generation and evaluation of new engineering design solutions during early product development. There are a variety of KE-approaches, such as knowledge-based engineering, case-based reasoning and programming, which have been used in research to develop design for manufacturing methods and applications. There are, however, opportunities for research where several approaches and their interdependencies, to create a transparent picture of how KE can be used to support engineering design, are investigated. The aim of the research presented in this thesis is to create new methods for design for manufacturing, by using several approaches of KE, and find the beneficial and less beneficial aspects of these methods in comparison to each other and earlier research. This thesis presents methods and applications for design for manufacturing using KE. KE has been employed in several ways, namely rule-based, rule-, programmingand finite element analysis (FEA)-based, and ruleand plan-based, which are tested and compared with each other. Results show that KE can be used to generate information about manufacturing in several ways. The rule-based way is suitable for supporting life-cycle commitments, as engineering design and manufacturing can be integrated with maintenance and performance predictions during early engineering design, though limited to the firing of production rules. The rule-, programmingand FEA-based way can be used to integrate computer-aided design tools and virtual manufacturing for non-linear stress and displacement analysis. This way may also bridge the gap between engineering designers and computational experts, even though this way requires a larger effort to program than the rule-based. The ruleand planbased way can enable design for manufacturing in two fashions – based on earlier manufacturing plans and based on rules. Because earlier manufacturing plans, together with programming algorithms, can handle knowledge that may be more intricate to capture as rules, as opposed to the time demanding routine work that is often automated by means of rules, several opportunities for designing for manufacturing exist.

Methods and Applications

United States. Dept. of Energy. Office of Basic Energy Sciences (Solid-State Solar-Thermal Energy Conversion Center)

Condensation heat transfer on superhydrophobic surfaces

Biomimetic nanosurfaces with distinct wettability and versatility have found special enthusiasm in both fundamental research and industrial applications. With the advent of nanotechnology, it is doable to acclimate surface architecture and surface chemistry to attain superhydrophobicity. The uniqueness of superhydrophobic surfaces arises from various phenomenal advances, and its progress is expected to continue for decades in the future. In this Review Article, we discuss recent progress made in defining physical aspects of numerical modeling, experimental practices adopted, and applications of superhydrophobic surfaces. First, we revisit various classical models of superhydrophobicity and recent theoretical advances achieved related to the wetting phenomena. Subsequently, we emphasize various precursors and advance fabrication strategies adopted to fabricate superhydrophobic surfaces. In the following section, we take up various potential applications and appropriate working principles to explain wettability phenomena. Finally, some general conclusions are drawn along with proposed guidelines for designing robust superhydrophobic coatings.

Superhydrophobic Surfaces: Insights from Theory and Experiment.

A wide variety of coating methods and materials are available for different coating applications with a common purpose of protecting a part or structure exposed to mechanical or chemical damage. A benefit of this protective function is to decrease manufacturing cost since fabrication of new parts is not needed. Available coating materials include hard and stiff metallic alloys, ceramics, bio-glasses, polymers, and engineered plastic materials, giving designers a variety freedom of choices for durable protection. To date, numerous processes such as physical/chemical vapor deposition, micro-arc oxidation, sol–gel, thermal spraying, and electrodeposition processes have been introduced and investigated. Although each of these processes provides advantages, there are always drawbacks limiting their application. However, there are many solutions to overcome deficiencies of coating techniques by using the benefits of each process in a multi-method coating. In this article, these coating methods are categorized, and compared. By developing more advanced coating techniques and materials it is possible to enhance the qualities of protection in the future.

On Coating Techniques for Surface Protection: A Review

Surface Modification of Polymers: Methods and Applications

Understanding wettability and mechanisms of wetting transition are important for design and engineering of superhydrophobic surfaces. There have been numerous studies on the design and fabrication of superhydrophobic and omniphobic surfaces and on the wetting transition mechanisms triggered by liquid evaporation. However, there is a lack of a universal method to examine wetting transition on rough surfaces. Here, we introduce force zones across the droplet base and use a local force balance model to explain wetting transition on engineered nanoporous microstructures, utilizing a critical force per unit length (FPL) value. For the first time, we provide a universal scale using the concept of the critical FPL value which enables comparison of various superhydrophobic surfaces in terms of preventing wetting transition during liquid evaporation. In addition, we establish the concept of contact line-fraction theoretically and experimentally by relating it to area-fraction, which clarifies various arguments about the validity of the Cassie-Baxter equation. We use the contact line-fraction model to explain the droplet contact angles, liquid evaporation modes, and depinning mechanism during liquid evaporation. Finally, we develop a model relating a droplet curvature to conventional beam deflection, providing a framework for engineering pressure stable superhydrophobic surfaces.

/pdf/explaining-evaporation-triggered-wetting-transition-using-48l7sut830.pdf

Explaining Evaporation-Triggered Wetting Transition Using Local Force Balance Model and Contact Line-Fraction.

Scalable manufacturing of structured materials with engineered nanoporosity is critical for applications in energy storage devices (i.e., batteries and supercapacitors) and in the wettability control of surfaces (i.e., superhydrophobic and superomniphobic surfaces). Patterns formed in arrays of vertically aligned carbon nanotubes (VA-CNTs) have been extensively studied for these applications. However, the as-deposited features are often undesirably altered upon liquid infiltration and evaporation because of capillarity-driven aggregation of low density CNT forests. Here, it is shown that an ultrathin, conformal, and low-surface-energy layer of poly perfluorodecyl acrylate, poly(1H,1H,2H,2H-perfluorodecyl acrylate) (pPFDA), makes the VA-CNTs robust against surface-tension-driven aggregation and densification. This single vapor-deposition step allows the fidelity of the as-deposited VA-CNT patterns to be retained during wet processing, such as inking, and subsequent drying. It is demonstrated how to establish omniphobicity or liquid infiltration by controlling the surface morphology. Retaining a crust of entangled CNTs and pPFDA aggregates on top of the patterned VA-CNTs produces micropillars with re-entrant features that prevent the infiltration of low-surface-tension liquids and thus gives rise to stable omniphobicity. Plasma treatments before and after polymer deposition remove the crust of entangled CNTs and pPFDA aggregates and attach hydroxyl groups to the CNT tips, enabling liquid infiltration yet preventing densification of the highly porous CNTs. The latter observation demonstrates the protective character of the pPFDA coating with the potential application of these surfaces for direct contact printing of microelectronic features.

/pdf/stable-wettability-control-of-nanoporous-microstructures-by-2pyei07eyi.pdf

Stable Wettability Control of Nanoporous Microstructures by iCVD Coating of Carbon Nanotubes.

The ability of hydrophobic surfaces to repel impinging liquid droplets is important in applications ranging from self-cleaning of solar panels to avoiding ice formation in freezing rain environments. In quest of maximizing water repellency, modification of droplet dynamics and subsequent reduction of contact time have been achieved by incorporating macrotexture on the superhydrophobic surfaces. However, the dynamics of low temperature water, and other viscous liquid droplets impacting anti-wetting surfaces with macrotextures is not well explored. Here, we investigate the effect of viscosity on the bouncing dynamics of liquid droplets impacting macrotextured superamphiphobic surfaces using various glycerol-water mixtures as model liquids at different impacting conditions. We demonstrate that the changes of reduction in contact times by macrotextures due to the increasing viscosity are in opposite trends at low and at high impact velocities. Since macrotexture executes substantial contact time reduction for the droplets which exhibit splitting after the impact, a preliminary model for predicting the minimum impact velocity to observe droplet splitting by macrotexture is proposed considering the important parameters of an impinging droplet along with the surface characteristics and the macrotexture size. This work aims to provide an insight on several possible outcomes of viscous droplets impacting on the macrotextured surfaces and a model that will help to design the desired superamphiphobic surfaces capable of exhibiting reduced contact time and enhanced repellency of low-temperature water droplets (such as freezing rain) and other viscous liquids (such as oils) under different impacting conditions.

/pdf/effect-of-superamphiphobic-macrotextures-on-dynamics-of-fcb5vkgi9v.pdf

Rama Kishore Annavarapu

Papers

Surface Modification of Polymers: Methods and Applications

Explaining Evaporation-Triggered Wetting Transition Using Local Force Balance Model and Contact Line-Fraction.

Stable Wettability Control of Nanoporous Microstructures by iCVD Coating of Carbon Nanotubes.

Effect of superamphiphobic macrotextures on dynamics of viscous liquid droplets

Stable Wettability Control of Nanoporous Microstructures by iCVD Coating of Carbon Nanotubes