The rheological properties of polymer melts and polymer/blowing agent (BA) solutions are determined experimentally and the influences of material rheological properties and crystallization on low-density foaming behaviour of polylactic acid (PLA) are investigated. Understanding the rheological properties of foaming polymers allows the optimization of polymer chemical structure and the development of technologies that produce desired cell morphologies. Although the technology for producing CO2-blown polystyrene (PS) foams is well established, the rheological properties of a PS/CO2 solution, especially its extensional property, are not well understood. In this study, these properties are determined with an in-house developed, online technique, and the measured data are compared with those from commercial rheometers. The online measurement system consists of a tandem foam extrusion system and a die for measuring pressure drops. Shear viscosity is determined from the pressure drop over a straight rectangular channel, while planar extensional viscosity from the pressure drop over a thin hyperbolic channel, taking into account the pressure drop due to shearing. Measured viscosities of the polystyrene without CO2 compare well with those from commercial rheometers. With the presence of dissolved CO2, both the shear and extensional viscosities of the polystyrene are significantly reduced. The influence of CO2 on the two viscosities is found to be similar to an increase of temperature. Polylactic acid is the first mass-produced biodegradable polymer, and has potential to replace petroleum-based polymers in foaming applications. In this study, the influences of material rheological properties and crystallization on the low-density, microcellular extrusion foaming behaviour of polylactic acids (PLAs) are investigated. Comparisons are made between linear and branched PLAs and between amorphous and crystalline PLAs. The branched PLAs are found to produce foams with higher expansion ratios and reduced open-cell content compared to the linear PLA. The foaming behaviour of the linear PLA, then, is significantly improved by adding a small amount of long-chain-branched PLA. The improved cell structure with branched PLAs is attributed to their relatively high melt strength and strain to break. For the first time, it is shown that crystallization, induced by cooling and macroscopic flow during processing, increases melt strength, which aids the production of low-density foams.

In the past few decades, significant progress has been made in addressing control problems for a variety of engineering systems having smooth dynamics. In practice, one often encounters also non-smooth systems in various branches of science and engineering, such as for example mechanical systems subject to impact. Motivated by the read/write head flying height regulation problem in hard disk drives, where the close proximity of the read/write head to the disk surface results in intermittent contact between the two and a bimodal system behavior, this thesis studies the output regulation problem in switched bimodal linear systems against known and unknown exogenous input signals. The regulation problems in bimodal systems presented in this thesis are solved within sets of Q-parameterized controllers, in which the Q parameters are designed to yield internal stability and exact output regulation in the closed loop switched system. The proposed parameterized controllers are constructed mainly in two steps. The first step is based on constructing a switched observer-based state feedback central controller for the switched linear system. The second step involves augmenting the switched central controller with additional dynamics (i.e. Q parameter) to construct a parameterized set of switched controllers. Based on the proposed sets of Q-parameterized controllers, four main regulation problems are addressed and corresponding regulator synthesis algorithms are proposed. The first problem concerns regulation against known deterministic exogenous inputs, where no stability or structural constraints are imposed on the Q parameter. The second problem is similar to the first, except that the Q parameter is constrained to be a linear combination of basis functions. This structure of the Q parameter is considered in the rest of the thesis. The third problem involves regulation against exogenous inputs involving known deterministic components and unknown random components, and where the regulator is designed subject to an H2 performance constraint. The last problem involves the development of adaptive regulators against unknown sinusoidal exogenous inputs. The different regulator synthesis algorithms are developed based on solving sets of linear matrix inequalities or bilinear matrix inequalities. The last two proposed regulation methods are successfully evaluated on an experimental setup motivated by the flying height regulation problem in hard disk drives, and involving a mechanical system with switched dynamics.

An initial evaluation of the scalability of extrusion foaming technology is conducted in this thesis. Both lab- and pilot-scale foam extrusion systems along with annular dies and flat dies were used to investigate the effects of extrusion system scale on the foam expansion. The effects of the processing conditions including die temperature and blowing agent content on the volume expansion of extruded polystyrene foams blown with carbon dioxide are presented. A systematic comparison of the effects of extrusion system scale on the expansion behavior of polystyrene foams blown with carbon dioxide at the consistent pressure-drop rate, demonstrated that the scale of the foam extrusion system does not affect the principles of the foaming process, and the effects of extrusion system size on the scale-up of foam techniques, such as shear rate and temperature uniformity, could be suppressed by tailoring the processing conditions and experimental parameters.

A prototype acoustic streaming pump for microfluidic applications was developed. A novel integration scheme was devised based on the acoustic reflector concept. Numerical simulations were conducted to predict the flow patterns around the transducer. Ultrasound transducers using P(VDF-TrFE) as the piezoelectric element were fabricated using lithography-based microfabrication technology. Silicon channels were fabricated using anisotropic etching. A heat-press bonding technique was adopted to bond the transducers with the silicon chips using CYTOP fluoropolymer as the adhesive. The piezoelectric transducers were characterized to have a resonance frequency of 82 MHz. Micro-PIV experiments were performed in the near and far-fields of the ultrasonic transducer/pump. The near field experiments showed complex flow patterns that could enhance mixing. Estimates of the pumping pressure were obtained using transient flow velocities in the far-field. Conservative estimates indicate the total back pressure the micropump can pump against is 39 Pa. Future research directions were suggested.

Effects of external vibrations (called g-jitter) on Marangoni convection in a liquid bridge were investigated on the International Space Station (ISS) and in ground-based experiments. In ISS, most dominant g-jitter frequency was noted to be ~110 Hz. ISS experiments suggested that the surface vibrations were mainly affected by the aspect ratio (length/diameter ratio), but not the imposed temperature gradient. Liquid bridge surface vibrations agreed well with Ichikawa et al.’s model. Ground-based experiments confirmed that increasing the volume ratio would cause the resonance frequency to increase. When a temperature difference was imposed between the upper and lower disks, for constant aspect and volume ratios, the resonance frequency tended to increase with the decreasing temperature difference. Furthermore, the shift in the resonance frequency due to a temperature difference, was found to be due to Marangoni convection and not due to reduced viscosity or surface tension of the fluid.

In this thesis, synchrotron radiography was utilized to image liquid water distributions in the porous polymer electrolyte membrane fuel cell (PEMFC) gas diffusion layers (GDLs). GDLs were compressed in an ex situ flow field apparatus with 1mm x 1mm channels, and injected with liquid water to study the effect of current density and microstructure on through-plane GDL liquid water distributions. The effect of the size of the water inlet on GDL liquid water distribution was also investigated. Micro-computed tomography was employed to characterize the effect of flow field compression on commercial and non-commercial GDLs. Porosity distributions of compressed GDLs were compared with those of uncompressed GDLs, and the effect of microstructure on the porosity was discussed. The experimental techniques documented in this thesis will inform future research, while the results will help modellers generate realistic GDL pore structures for multiphase flow simulations and validate their models.

In this study, crystal formation of polypropylene (PP) and poly lactic acid (PLA) in the presence of CO2 in foam extrusion process was investigated using a visualization chamber and a CCD camera. The role of pre-existing crystals on the foaming behavior of PP and PLA were studied by characterizing the foam morphology. Visualization results showed that crystals formed within the die before foaming and these crystals affect the cell nucleation behavior and expansion ratio of PP and PLA significantly. Due to the fast crystallization kinetics of PP, crystallinity should be optimum to achieve uniform cell structure with high cell density and high expansion ratio. In PLA, enhancement of crystallinity is crucial for getting foam with a high expansion ratio. It was also visualized that CO2 significantly suppresses the crystallization temperature in PP through the plasticization effect as well as its influence on flow induced crystallinity.

An initial evaluation of the scalability of extrusion foaming technology is conducted in this thesis. Both lab- and pilot-scale foam extrusion systems along with annular dies and flat dies were used to investigate the effects of extrusion system scale on the foam expansion. The effects of the processing conditions including die temperature and blowing agent content on the volume expansion of extruded polystyrene foams blown with carbon dioxide are presented. A systematic comparison of the effects of extrusion system scale on the expansion behavior of polystyrene foams blown with carbon dioxide at the consistent pressure-drop rate, demonstrated that the scale of the foam extrusion system does not affect the principles of the foaming process, and the effects of extrusion system size on the scale-up of foam techniques, such as shear rate and temperature uniformity, could be suppressed by tailoring the processing conditions and experimental parameters.

A prototype acoustic streaming pump for microfluidic applications was developed. A novel integration scheme was devised based on the acoustic reflector concept. Numerical simulations were conducted to predict the flow patterns around the transducer. Ultrasound transducers using P(VDF-TrFE) as the piezoelectric element were fabricated using lithography-based microfabrication technology. Silicon channels were fabricated using anisotropic etching. A heat-press bonding technique was adopted to bond the transducers with the silicon chips using CYTOP fluoropolymer as the adhesive. The piezoelectric transducers were characterized to have a resonance frequency of 82 MHz. Micro-PIV experiments were performed in the near and far-fields of the ultrasonic transducer/pump. The near field experiments showed complex flow patterns that could enhance mixing. Estimates of the pumping pressure were obtained using transient flow velocities in the far-field. Conservative estimates indicate the total back pressure the micropump can pump against is 39 Pa. Future research directions were suggested.

Effects of external vibrations (called g-jitter) on Marangoni convection in a liquid bridge were investigated on the International Space Station (ISS) and in ground-based experiments. In ISS, most dominant g-jitter frequency was noted to be ~110 Hz. ISS experiments suggested that the surface vibrations were mainly affected by the aspect ratio (length/diameter ratio), but not the imposed temperature gradient. Liquid bridge surface vibrations agreed well with Ichikawa et al.’s model. Ground-based experiments confirmed that increasing the volume ratio would cause the resonance frequency to increase. When a temperature difference was imposed between the upper and lower disks, for constant aspect and volume ratios, the resonance frequency tended to increase with the decreasing temperature difference. Furthermore, the shift in the resonance frequency due to a temperature difference, was found to be due to Marangoni convection and not due to reduced viscosity or surface tension of the fluid.