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<p>Fracture of silicon solar cells in photovoltaic (PV) modules are widely reported and a wellknown issue in the PV industry, since it is exposed to adverse climatic conditions and varying temperature loads. A commercial silicon solar cell is mainly composed of four different layers. This thesis investigates delamination failure and thermal fatigue failure due to alternating temperature loads using finite element method (FEM) simulation.</p> <p><br></p> <p>The delamination of the encapsulant (EVA) layer and the cell interface was simulated using</p> <p>finite element (FE) simulations in the COMSOL Multiphysics software. The adhesion between the</p> <p>layers were modeled using the cohesive zone model (CZM). The CZM parameters such as normal</p> <p>strength and penalty stiffness were used for the bilinear traction-separation law for the cohesive</p> <p>model in a 90-degree configuration. The critical energy release rate (𝐺𝐺𝑐𝑐) was experimentally calculated as one of the CZM parameters. A uniaxial tensile test of the upper layer of the cell was conducted to determine the material properties of the solar cell layers, and that information was</p> <p>later used for FE simulations. To validate the simulation, we compared the peeling force graph</p> <p>from the experiment and FE simulation, and it was found both graphs showed a maximum peeling</p> <p>force of 120 N.</p> <p><br></p> <p>Finite element simulations were also conducted to predict the stress variations in the silicon</p> <p>solar cell layer due to alternating temperatures. An alternating temperature function was developed</p> <p>using triangular waveform equations in the COMSOL Multiphysics software. For this simulation,</p> <p>a 3D model of the cell with a 90-degree peel arm was used, like in the peeling simulation. A</p> <p>maximum stress of 7.31 x 10−3 𝑁/𝑚𝑚2 was observed on the encapsulant (EVA)/cell layer, but no</p> <p>delamination was observed for the given temperature range. In future work, we plan to explore the</p> <p>calculation of fatigue life using thermal simulation to predict the reliability of a solar cell.</p>

Electrical bushings are a type of hollow or solid conductor withinsulation designed to allow a conductor to pass through a conductingbarrier without making electrical contact and are very important forsafe transportation of electricity. The bushings vary in size, but allbushings have a solid or hollow conductor.This project aims to investigate which resistivities of the siliconerubber, in combination with different air conditions for the airsurrounding the bushing (dry, average and humid air) and theirrespective resistivities, to see which combinations allow for anelectrical field that allows the bushing to safely work without beingdamaged. The different air conditions are an important factor since theyall correspond to different absolute humidities present in the air,which have a direct impact on the strength of the electrical fieldsurrounding the bushing. Since this cannot be done by hand, a computersoftware called COMSOL Multiphysics will be used. COMSOL is aMultiphysics software, meaning one can simulate many types of physics atonce. With the help of this software, and a model provided by HitachiEnergy, results could be found stating that dry air overall is the bestcondition of air for the bushing, followed by average (not either dry orhumid) air and lastly humid air.

This dissertation demonstrates the first of its kind distributed magnetic field sensor based on a fiber optic distributed acoustic sensing (DAS) scheme. Ferromagnetic nickel and Metglas® were dispersed internally within a fiber optic preform and then drawn on an in-house fiber optic draw tower to lengths in the kilometers. Due to the close proximity of the ferromagnetic metals and fiber optic core, the magnetostrictive strain response of the ferromagnetic materials when exposed to a magnetic field would perturbate within the fiber cladding and transfer that strain, internally, to the fiber optic core. Strain resulting from the magnetostrictive effect allows the DAS based sensor to accurately translate strain into readable magnetic field data. Due to the high sensitivity seen in this sensor design, multiparameter sources, acoustic and magnetic fields, were tested and validated and a three dimensional magnetic-field vector sensor was proposed. Numerical analysis of the novel sensor design was first implemented using COMSOL Multiphysics, where inputs such as magnetostrictive element shape, size, distance, and number were first investigated. Upon optimizing system constraints, the sensor design was further modified such that single mode operation was consistent across multiple fiber draws while retaining high strain transfer from the ferromagnetic elements to the fiber optic core. Ferromagnetic material selection was evaluated as a function of the saturation magnetostriction constants and a total of 4 modules were used to fully characterize the complex physics involved in this sensor design. All fabrication and testing were performed in-house using a full scale 3-story fiber draw tower and custom environmental testing stations to imitate naturally occurring events such as magnetic or acoustic point sources. A unique stacking method was used to embed ferromagnetic nickel and Metglas® into a fiber optic preform which when combined with a custom fiber draw process resulted in consistent multi-material fibers drawn to lengths of 1-km. In-house testing facilities included different types of electromagnetic generators, in addition to a soil test bed, and an outdoor test bed which allowed 100 meters of fiber to be tested simultaneously. All tested sensors demonstrated high strain transfer capabilities on the order of 0.01-10 μϵ depending on the materials used, ferromagnetic rod number, and core to metal spacing. Due to the sensitivity of the system the difference between AC and DC was distinct, and directional magnetostriction was studied. Transverse and longitudinal magnetic wave propagation was controlled through a solenoid and rectangular Helmholtz coil, both built in-house. A three-dimensional magnetic field vector sensor was proposed due to the success of the magnetic field sensor, and a design was proposed and initially tested to validate direction as a function of field strength and distance. To summarize, this dissertation explores the first fully distributed magnetic field sensor using DAS based techniques and one of the first multi-material fiber draw processes which can produce consistent single mode fiber up to 1-km. Due to extensive FEA modeling, multiple iterations of the magnetic sensor were fully characterized and an equation describing the relationship between sensor design and strain transfer has been created and validated experimentally. Multi-parameter tests including acoustic and magnetic fields were implemented and an algorithm was developed to separate the mixed signals. Finally, a test was performed to demonstrate the feasibility of sensing magnetic fields directionally. Cumulative results demonstrate a high-quality sensor alternative to current designs which may surpass other magnetic sensors due to innate multi-parameter capabilities, in addition to the inexpensive production cost and extremely long operating lengths. / Doctor of Philosophy / This dissertation demonstrates the first of its kind distributed magnetic field sensor based on a fiber optic distributed acoustic sensing (DAS) scheme. Ferromagnetic nickel and Metglas® were dispersed internally within a fiber optic preform and then drawn on an in-house fiber optic draw tower to lengths in the kilometers. Due to the close proximity of the ferromagnetic metals and fiber optic core, the magnetostrictive strain response of the ferromagnetic materials when exposed to a magnetic field would perturbate within the fiber cladding and transfer that strain, internally, to the fiber optic core. Strain resulting from the magnetostrictive effect allows the DAS based sensor to accurately translate strain into readable magnetic field data. Due to the high sensitivity seen in this sensor design, multiparameter sources, acoustic and magnetic fields, were tested and validated and a three dimensional magnetic-field vector sensor was proposed. Numerical evaluation of the sensing structure was perused before experimental testing using COMSOL Multiphysics. Experimental and numerical evaluations were compared and showed a high degree of certainty which allowed expedited design modifications. Sensor characterization included scanning electron microscopy, and electron diffraction spectroscopy, which provided insight into material composition and fiber polishing quality. Due to the high-quality results attained in the combined acoustic and magnetic field tests, a final design was proposed to gather magnetic field data as a vector, showing both magnitude and direction. The 3D magnetic field vector sensor was partially validated based on a test which compared intensity with distance and a design and methodology was proposed to fully test and characterize this design. To summarize, a novel magnetic field sensor, capable of multi-parameter sensing, was proposed and tested experimentally and numerically resulting in a robust and highly sensitive design. The work presented here provides some of the first insights into multi-material fiber fabrication, an equation which provides an estimated relationship between magnetostrictive strain transfer onto a fiber optic core and the perceived DAS based sensor results, as well as a first of its kind multi-parameter distributed acoustic and magnetic field sensor.

This thesis explores the potential of utilizing metal-based plasma sources as a sustainable solution for high-powered electric propulsion and its implications for future interplanetary travel. Focusing on the Vacuum Arc Thruster and the Variable Specific Impulse Magnetoplasma Rocket engine, the study encompasses numerical simulations, analytical comparisons, and performance analyses to assess the feasibility of metal plasma fuels in space missions.The numerical analysis employs COMSOL Multiphysics to delve into the magnetohydrodynamics behavior within the VAT. Such simulation setup could provide valuable insights. Although the numerical results are disappointing for this paper, there exist possibilities within future work. The main hurdle is the simulation of vacuum. There are workarounds in COMSOL's Vacuum System Modeling tool which was not available for this thesis. Also, the used material properties were not suited for this high temperature plasma environment. The lack of material properties is a consequence of the insufficient research in the metal plasma field.Performance analysis is conducted on both the VAT and VASIMR engine, exploring efficiency, thrust capabilities, and feasibility for interplanetary missions. The results demonstrate the potential of metal-based plasma sources to reduce dependence on Earth for refueling and decrease mission costs. It is found that aluminum and magnesium have similar performance as the argon gas used in the VASIMR.Although challenges exist, such as integration problems and availability of material properties for metals in plasma states, the study underscores the promise of metal plasma fuels for sustainable space exploration. By advancing high-powered electric propulsion technologies, we move closer to realizing humanity's ambitious journey to distant celestial bodies. This research paves the way for future innovations, enabling a more self-sustaining space economy and unlocking new horizons of interplanetary travel.

Lightning current with high amplitude disseminates through the body of aircraft and causes physical damages including the delamination and puncture of materials. Also , such high-amplitude and high-frequency current could interfere with electronic devices through electromagnetic coupling with the conductive interfaces of an airplane. Hence, robust protection against lighting strike is essential in the aerospace industry. Carbon Fiber Reinforced Polymer (CFRP) Matrix Composites have become significant alternatives to conventional metal-base materials. Despite the superior physical and structural properties of CFRP composites, these materials are vulnerable to lightning strikes due to the low electrical conductivity compared to the metal counterpart. Many researchers have been working on the lightning strike damage mitigation of CFRP composites by increasing the electrical conductivity of materials. Conventional methods are adding conductive layers such as metal foil and copper mesh to the composite structures. These layers are added to the composite structure during the manufacturing process and are placed at the top layer for the effective bypassing of lightning current to the ground. While adding the conductive layers reduces the lightning strike damage significantly, the industry is more interested in using conductive nanofillers to prevent the corrosion of metal layers in contact with carbon fibers and to avoid the higher weight of conductive layers than nanofillers. The lightning damage mitigation methods are studied by applying lightning strike current to the CFRP composites using an impulse current generator. Conventional lightning strike damage tolerance of CFRP composites are prone to misinterpretation. The risk of misinterpretation originates from the lack of standards clearly defining testbed design requirements including electrode size and ground electrode edge configuration. In this dissertation, the effects of testbed configuration including discharge and ground electrode on lightning strike damage evaluation studies are demonstrated. Finite element analysis is applied to perform the simulations through the COMSOL Multiphysics to validate the experimental test results. Furthermore, after improving the testbed design, carbon black was added to the CFRP composites as a cost-effective additive for lightning strike damage mitigation performance. Correlations between lightning strike damage intensity and the added carbon black fillers as well as with other additive nanofillers are reported.

Throughout recent years, computer based programs has been applied to solve and analyze industrial problems. One of these developed programs is the Computational Fluid Dynamics (CFD) program. The purpose of implementing CFD analysis is to solve complex flow behavior which is not possible with ordinary calculus. The extensive application of CFD in the industry is a result of improved commercial CFD codes  in terms of more advance partial differential equations (PDE) describing various physical phenomena, CAD and mesh-grid generating tools and improved graphical user interfaces (GUI). Today, CFD usage has extended to fields such as aerodynamic, chemical process engineering, biomedical engineering and drying technology. As there is an on-going expansion of CFD usages in the industry, certain issues need to be addressed as they are frequently encountered. The general demand for simulation of larger control volumes and more advanced flow processes result in extensive requirement of computer resources. Numerous complex flow topics today require computer cluster networks which are not accessible for every company. The second issue is the implementation of commercial CFD codes in minor industrial companies is utilized as a black box based on the knowledge on fluid mechanic theory. A vital part of the simulation process is the evaluation of data through visual analysis of flow patterns, analysis on the sensitivity of the mesh grid, investigation of quantitative parameters such as pressure loss, velocity, turbulence intensity etc. Moreover, increased partnerships between industry and the academic world involving various CFD based design processes generally yields to a verbal communication interface which is a crucial step in the process given the fact of the level of dependency between both sides. The aim of this thesis is to present methods of CFD analysis based on these issues. In paper I, a heuristically determined design process of the geometry near the front trap door of an internal duct system was achieved by implementing the CFD code COMSOL MultiPhysics as a communication tool. The design process was established by two counterparts in the project in which CFD calculations and geometry modifications were conducted separately. Two design criteria presenting the pressure drop in duct and the outflow uniformity was used to assess geometry modifications conducted by a CAD-engineer. The geometry modifications were based on visual results of the flow patterns. The geometry modifications confirmed an improvement in the geometry as the pressure drop was reduced with 23% and the uniformity was increased with 3%. In paper II, volume-averaged equations were implemented in a tube-fin heat exchanger in order to simulate airflow. Focus was on achieving a correct volume flow rate and pressure drop (V-p) correlation. The volume averaged model (VAM) is regarded as a porous medium in which the arrangement of fins and tube bundles are replaced with volume-averaged equations. Hence, the computational time was reduced significantly for the VAM model. Moreover, experimental results of the (V-p) correlation showed good agreement with the VAM model.

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This thesis describes methods for improving sensitivity in rapid singleplex and multiplex microarray assays. The assays utilize the optical characteristics of colloidal gold nanoparticles for the colorimetric detection of proteins. Multiplexed detection in sandwich immunoassays is limited by cross-reactivity between different detection antibodies. The cross-reactivity between antibodies can contribute to increased background noise - decreasing the Limit-of-Detection of the assay - or generate false positive signals. Paper I shows improved assay sensitivity in a multiplexed vertical flow assay by the application of ultrasonic energy to the gold nanoparticles functionalized with detection antibodies. The ultrasonication of the antibody conjugated gold nanoparticles resulted in a 10 000 fold increase in sensitivity in a 3-plex assay. COMSOL Multiphysics was used to simulate the acoustical energy of the probe used in Paper I for obtaining an indication of the size and direction of the forces acting upon the functionalized gold nanoparticles. In Paper II, it was studied if different gold nanoparticle conjugation methods and colorimetric signal enhancement of the gold nanoparticle conjugates could influence the sensitivity of a paper-based lateral flow microarray assay, targeting cardiac troponin T for the rapid diagnostics of acute myocardial infarction. Ultrasonication and signal enhancement of the detection gold nanoparticles has the potential of improving the sensitivity of paper based assays and expanding their potential future applications. / <p>QC 20170911</p>

The aim of this thesis is to design a kilowatt three-phase step-down rotary transformer for a permanent magnet DC motor. The permanent magnet DC motor has an on-rotor drive system, and therefore requiring a power supply that can transfer power to its drive unit without mechanical contact. The rotary transformer has a detached magnetic coupling structure that qualifies it as a potential method for the wireless power transfer. This thesis studies the rotary transformer as a static device, focusing on its core loss. By using a transient finite element analysis of COMSOL Multiphysics and an iron loss prediction model, the rotary transformer was optimized in terms of efficiency and power density for the on-rotor drive system through proper material selection and geometry exploration. After this, a mechanical design, which based on a literature review of the influences of manufacturing processes on electrical steels, was proposed for realizing the core fabrication and the rotary transformer assembly. The results show that the rotary transformer can step down 400 V/50 Hz three-phase voltage to 13.15V in a Delta-wye connection and output 1.17kW power over an air-gap of 0.3mm with 95.94% overall efficiency. The proposed mechanical design enables the transformer to minimize the core loss and the manufacturing cost. Without using resonant inductive coupling, this transformer design simplifies the power supply for the motor, thereby decreasing the motor manufacturing and maintenance cost.