Publications

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Polymeric foam systems are widely used in industrial applications due to their low weight and abilities to thermally insulate and isolate vibration. However, processing of these foams is still not well understood at a fundamental level. The precursor foam of interest starts off as a liquid phase emulsion of blowing agent in a thermosetting polymer. As the material is heated either by an external oven or by the exothermic reaction from internal polymerization of the suspending fluid, the blowing agent boils to produce gas bubbles and a foamy material. A series of experiments have been performed to allow observation of the foaming process and the collection of temperature, rise rate, and microstructural data. Microfocus video is used in conjunction with particle image velocimetry (PIV) to elucidate the boundary condition at the wall. These data provide input to a continuum level finite element model of the blowing process. PIV is used to measure the slip velocity of foams with a volume fraction range of 0.50 to 0.71. These results are in agreement with theoretical predictions which suggest that at high volume fractions the bubbles would exhibit jamming behavior and slip at the wall. At these volume fractions, the slip velocity profile has a shear profile shape near the side walls and a plug flow shape at the center. The shape of the velocity profile is in agreement with previous experimental work investigating different foam systems. As time increases, the available blowing agent decreases, the volume fraction increases, the viscosity increases, and the average slip velocity decreases, but the slip velocity profile maintains the plug-shear shape. © 2008 American Institute of Physics.

We developed prototype chemistry for nucleic acid hybridization on our bead-based diagnostics platform and we established an automatable bead handling protocol capable of 50 part-per-billion (ppb) sensitivity. We are working towards a platform capable of parallel, rapid (10 minute), raw sample testing for orthogonal (in this case nucleic acid and immunoassays) identification of biological (and other) threats in a single sensor microsystem. In this LDRD we developed the nucleic acid chemistry required for nucleic acid hybridization. Our goal is to place a non-cell associated RNA virus (Bovine Viral Diarrhea, BVD) on the beads for raw sample testing. This key pre-requisite to showing orthogonality (nucleic acid measurements can be performed in parallel with immunoassay measurements). Orthogonal detection dramatically reduces false positives. We chose BVD because our collaborators (UC-Davis) can supply samples from persistently infected animals; and because proof-of-concept field testing can be performed with modification of the current technology platform at the UC Davis research station. Since BVD is a cattle-prone disease this research dovetails with earlier immunoassay work on Botulinum toxin simulant testing in raw milk samples. Demonstration of BVD RNA detection expands the repertoire of biological macromolecules that can be adapted to our bead-based detection. The resources of this late start LDRD were adequate to partially demonstrate the conjugation of the beads to the nucleic acids. It was never expected to be adequate for a full live virus test but to motivate that additional investment. In addition, we were able to reduce the LOD (Limit of Detection) for the botulinum toxin stimulant to 50 ppb from the earlier LOD of 1 ppm. A low LOD combined with orthogonal detection provides both low false negatives and low false positives. The logical follow-on steps to this LDRD research are to perform live virus identification as well as concurrent nucleic acid and immunoassay detection.

A series of experiments has been performed to allow observation of the foaming process and the collection of temperature, rise rate, and microstructural data. Microfocus video is used in conjunction with particle image velocimetry (PIV) to elucidate the boundary condition at the wall. Rheology, reaction kinetics and density measurements complement the flow visualization. X-ray computed tomography (CT) is used to examine the cured foams to determine density gradients. These data provide input to a continuum level finite element model of the blowing process.

Many weapons components (e.g. firing sets) are encapsulated with blown foams. Foam is a strong lightweight material--good compromise between conflicting needs of structural stability and electronic function. Current foaming processes can lead to unacceptable voids, property variations, cracking, and slipped schedules which is a long-standing issue. Predicting the process is not currently possible because the material is polymerizing and multiphase with changing microstructure. The goals of this project is: (1) Produce uniform encapsulant consistently and improve processability; (2) Eliminate metering issues/voids; (3) Lower residual stresses, exotherm to protect electronics; and (4) Maintain desired properties--lightweight, strong, no delamination/cracking, and ease of removal. The summary of achievements in the first year are: (1) Developed patentable chemical foaming chemistry - TA; (2) Developed persistent non-curing foam for systematic evaluation of fundamental physics of foams--Initial testing of non-curing foam shows that surfactants very important; (3) Identified foam stability strategy using a stacked reaction scheme; (4) Developed foam rheology methodologies and shear apparatuses--Began testing candidates for shear stability; (5) Began development of computational model; and (6) Development of methodology and collection of property measurements/boundary conditions for input to computational model.

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Here, we have developed a novel flow chamber which imposes a controlled axisymmetric stagnation flow to enable the study of external flow effects on coalescence dynamics. This system allows for the first time the precise positioning of a drop in a three dimensional flow and additionally enforces a highly symmetric flow around the drop. We focus on the study of a single drop approaching a stationary flat plane as this is analogous to two drops approaching each other. A single drop is created and then guided along the unsteady center line of a stagnation flow. The real time computer control algorithm analyzes video images of the drop in two orthogonal planes and manipulates flow restricting valves along the four outlets of the flow. We demonstrate using particle image velocimetry that the computer control not only controls the drop position but also ensures a symmetric flow inside the flow chamber. Finally, this chamber will enable a detailed investigation of the drainage of the thin film between the drop and the lower surface in order to probe the effect of external flow on coalescence.

Capillary condensation of water can have a significant effect on rough surface adhesion. To explore this phenomenon between micromachined surfaces, the authors perform microcantilever experiments as a function of surface roughness and relative humidity (RH). Below a threshold RH, the adhesion is mainly due to van der Waals forces across extensive noncontacting areas. Above the threshold RH, the adhesion jumps due to capillary condensation and increases towards the upper limit of Γ = 144 mJ/m2. A detailed model based on the measured surface topography qualitatively agrees with the experimental data only when the topographic correlations between the upper and lower surfaces are considered. © 2007 American Institute of Physics.

We have investigated a novel emulsion interfacial filter that is applicable for a wide range of materials, from nano-particles to cells and bacteria. This technology uses the interface between the two immiscible phases as the active surface area for adsorption of targeted materials. We showed that emulsion interfaces can effectively collect and trap materials from aqueous solution. We tested two aqueous systems, a bovine serum albumin (BSA) solution and coal bed methane produced water (CBMPW). Using a pendant drop technique to monitor the interfacial tension, we demonstrated that materials in both samples were adsorbed to the liquid-liquid interface, and did not readily desorb. A prototype system was built to test the emulsion interfacial filter concept. For the BSA system, a protein assay showed a progressive decrease in the residual BSA concentration as the sample was processed. Based on the initial prototype operation, we propose an improved system design.

The goal of this project was to design, build and test novel diagnostics to probe the effect of hydrodynamic forces on coalescence dynamics. Our investigation focused on how a drop coalesces onto a flat surface which is analogous to two drops coalescing, but more amenable to precise experimental measurements. We designed and built a flow cell to create an axisymmetric compression flow which brings a drop onto a flat surface. A computer-controlled system manipulates the flow to steer the drop and maintain a symmetric flow. Particle image velocimetry was performed to confirm that the control system was delivering a well conditioned flow. To examine the dynamics of the coalescence, we implemented an interferometry capability to measure the drainage of the thin film between the drop and the surface during the coalescence process. A semi-automated analysis routine was developed which converts the dynamic interferogram series into drop shape evolution data.

Interfacial adhesion is an important factor in determining the performance and reliability of microelectromechanical systems (MEMS). Van der Waals dispersion forces are the dominant adhesion mechanism in the low relative humidity (RH) regime. At small roughness values, adhesion is mainly due to van der Waals dispersion forces acting across extensive non-contacting areas and is related to 1/Dave2, where Dave is the average surface separation. These contributions must be considered due to the close proximity of the surfaces, which is a result of the planar deposition technology. At large roughness values, van der Waals forces at contacting asperities become the dominating contributor to the adhesion. Capillary condensation of water has a significant effect on rough surface adhesion in the moderate to high RH regime. Above a threshold RH, which is a function of the surface roughness, the adhesion jumps due to meniscus formation at the interface and increases rapidly towards the upper limit of Γ=2γcosθ=44 mJ/m2, where γis the liquid surface energy and θis the contact angle. Copyright © 2006 by ASME.

We present an active method for mixing fluid streams in microchannels at low Reynolds number with no dead volume. To overcome diffusion limited mixing in microchannels, surface acoustic wave streaming offers an extremely effective approach to rapidly homogenize fluids. This is a pivotal improvement over mixers based on complex 3D microchannels which have significant dead volume resulting in trapping or loss of sample. Our micromixer is integrable and highly adaptable for use within existing microfluidic devices. Surface acoustic wave devices fabricated on 128° YX LiNbO₃ permitted rapid mixing of flow streams as evidenced by fluorescence microscopy. Longitudinal waves created at the solid-liquid interface were capable of inducing strong nonlinear gradients within the bulk fluid. In the highly laminar regime (Re = 2), devices achieved over 93% mixing efficacy in less than a second. Micro-particle imaging velicometry was used to determine the mixing behavior in the microchannels and indicated that the liquid velocity can be controlled by varying the input power. Fluid velocities in excess of 3 cm•s^-1 were measured in the main excitation region at low power levels (2.8mW). We believe that this technology will be pivotal in the development and advancement of microfluidic devices and applications.

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Nearly every manufacturing and many technologies central to Sandia's business involve physical processes controlled by interfacial wetting. Interfacial forces, e.g. conjoining/disjoining pressure, electrostatics, and capillary condensation, are ubiquitous and can surpass and even dominate bulk inertial or viscous effects on a continuum level. Moreover, the statics and dynamics of three-phase contact lines exhibit a wide range of complex behavior, such as contact angle hysteresis due to surface roughness, surface reaction, or compositional heterogeneities. These thermodynamically and kinetically driven interactions are essential to the development of new materials and processes. A detailed understanding was developed for the factors controlling wettability in multicomponent systems from computational modeling tools, and experimental diagnostics for systems, and processes dominated by interfacial effects. Wettability probed by dynamic advancing and receding contact angle measurements, ellipsometry, and direct determination of the capillary and disjoining forces. Molecular scale experiments determined the relationships between the fundamental interactions between molecular species and with the substrate. Atomistic simulations studied the equilibrium concentration profiles near the solid and vapor interfaces and tested the basic assumptions used in the continuum approaches. These simulations provide guidance in developing constitutive equations, which more accurately take into account the effects of surface induced phase separation and concentration gradients near the three-phase contact line. The development of these accurate models for dynamic multicomponent wetting allows improvement in science based engineering of manufacturing processes previously developed through costly trial and error by varying material formulation and geometry modification.

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The present document summarizes the experimental efforts of a three-year study funded under the Laboratory Directed Research and Development program of Sandia National Laboratories. The Innovative Diagnostics LDRD project was designed to develop new measurement capabilities to examine the interaction of a propulsive spin jet in a transonic freestream for a model in a wind tunnel. The project motivation was the type of jet/fin interactions commonly occurring during deployment of weapon systems. In particular, the two phenomena of interest were the interaction of the propulsive spin jet with the freestream in the vicinity of the nozzle and the impact of the spin rocket plume and its vortices on the downstream fins. The main thrust of the technical developments was to incorporate small-size, Lagrangian sensors for pressure and roll-rate on a scale model and include data acquisition, transmission, and power circuitry onboard. FY01 was the final year of the three-year LDRD project and the team accomplished much of the project goals including use of micron-scale pressure sensors, an onboard telemetry system for data acquisition and transfer, onboard jet exhaust, and roll-rate measurements. A new wind tunnel model was designed, fabricated, and tested for the program which incorporated the ability to house multiple MEMS-based pressure sensors, interchangeable vehicle fins with pressure instrumentation, an onboard multiple-channel telemetry data package, and a high-pressure jet exhaust simulating a spin rocket motor plume. Experiments were conducted for a variety of MEMS-based pressure sensors to determine performance and sensitivity in order to select pressure transducers for use. The data acquisition and analysis path was most successful by using multiple, 16-channel data processors with telemetry capability to a receiver outside the wind tunnel. The development of the various instrumentation paths led to the fabrication and installation of a new wind tunnel model for baseline non-rotating experiments to validate the durability of the technologies and techniques. The program successfully investigated a wide variety of instrumentation and experimental techniques and ended with basic experiments for a non-rotating model with jet-on with the onboard jets operating and both rotating and non-rotating model conditions.