Microchannel process technology (MPT) offers several advantages to the field of nanomanufacturing: 1) improved process control over very short time intervals owing to shorter diffusional distances; and 2) reduced reactor size due to high surface area to volume ratios and enhanced heat and mass transfer. The objective of this thesis was to consider how nanomaterials, produced in part using MPT, could be used to solve problems associated with the fabrication of MPT devices. Specifically, many MPT devices are produced using transient liquid-phase brazing involving an electroplated interlayer consisting of a brazing alloy designed for melting temperature suppression. Unfortunately, these alloys can form brittle secondary phases which significantly reduce bond strength. In contrast, prior efforts have shown that it is possible to leverage the size-dependent properties of nanomaterials to suppress brazing temperatures. In this prior work, thin films of off-the-shelf elemental nanoparticles were used as interlayers yielding joints with improved mechanical properties. In the present investigation, efforts have been made to characterize the synthesis and deposition of various elemental nanoparticle suspensions for use in the transient liquid-phase brazing of aluminum and stainless steel. Advances were used to demonstrate the nanoparticle-assisted diffusion brazing of a microchannel array. In the first section, a silver nanoparticle (AgNP) interlayer was produced for the diffusion brazing of heat exchanger aluminum. Efforts are made to examine the effect of braze filler particle size (~5 nm and ~50 nm) and processing parameters (heating rate: 5ºC/min and 25ºC/min; brazing temperature: 550ºC and 570ºC) on thin coupons of diffusion-brazed 3003 Al. A tensile strength of 69.7 MPa was achieved for a sample brazed at 570°C for 30 min under 1 MPa with an interlayer thickness of approximately 7 μm. Further suppression of the brazing temperature to 500ºC was achieved by sputtering a 1 µm thick layer of Cu before depositing a 5 nm thick film of AgNPs resulting in a lap shear strength of 45.3±0.2 MPa. In the middle section of this thesis, several techniques are investigated for the synthesis of sub 10 nm diameter nickel nanoparticles (NiNPs) to be used in the diffusion brazing of 316L stainless steel. The average NiNP size was varied from 9.2 nm to 3.9 nm based on the synthesis technique, solvent and reducing agent used. Conventional wet-chemical synthesis using NiCl₂.6H₂O in ethylene glycol (solvent) and N₂H₄.H₂O (reducing agent) resulted in the formation of 5.4 ± 0.9 nm NiNPs. Continuous flow synthesis using a microchannel T-mixer (barrel diameter of 521µm) and a 10 second residence time of reactants in a bath temperature of 130ºC resulted in a particle size of with 5.3 ± 1 nm. To make the synthesis safer and less energy intense, microwave heating was used along with less toxic Ni(CH₃CO₂)₂·4H₂O (nickel salt), propylene glycol (solvent) and NaPH₂O₂ (reducing agent) yielding 3.9 ± 0.8 nm diameter NiNPs. For the final section, nickel nanoparticles were synthesized using NiCl₂.6H₂O (nickel salt), de-ionized water (solvent), NaBH₄ (co-reducing agent), N₂H₄.H₂O (reducing agent) and polyvinylpyrolidone (capping agent) yielding 4.2 ± 0.6 nm NiNP. Several deposition techniques were investigated for controlling film thickness and uniformity in the diffusion brazing of 316L stainless steel (SS). Using in-house prepared NiNP and automated dispensing, a hermetic joint up to 70 psi (tested pressure) was obtained in 316L SS substrates under brazing conditions of 800ºC, 2 MPa and 30 min. Throughout the course of this thesis, techniques used for characterizing nanoparticles, films and joints included FT-IR, XRD, SEM, TEM, HRTEM, EDS, EPMA, DSC, mass spectrometry, and lap-shear testing. / Graduation date: 2012

Hydrogen has been shown to be a promising replacement for fossil fuels for use in light duty vehicles because it is a clean, renewable and plentiful resource with a high gravimetric energy density. However, in order to obtain an acceptable volumetric energy density, densification of the hydrogen is required. Adsorptive materials have been shown in the literature to increase volumetric and gravimetric storage densities. A major issue with adsorptive storage is that the adsorption process generates heat and optimal storage conditions are at temperatures below 100 K at pressures up to 50 atm. There is a need to develop heat exchanging architecture that enables adsorbents to be a viable method for hydrogen storage by managing the thermal environment of the storage tank. Based on previous modeling efforts to determine an acceptable bed module height for removal of heat via microchannel cooling plates, a thermal management system has been designed and tested capable of removing the heat of adsorption within adsorbent-filled hydrogen storage tanks. The system uses liquid nitrogen cooling to maintain tank temperatures of below 80 K at 50 atm. System studies show that the microchannel architecture offers a high cooling capacity with about a 6% displacement volume. Simulations and experiments have been conducted to evaluate the design for the cooling capacity, pressure drop, and flow distribution between and across the cooling plates, stress due to the pressurized environment, and thermal stress. Cost models have been developed to demonstrate that the system can be manufactured for a reasonable cost at high production volumes. Experimental results show that the modular system offers an acceptable cooling capacity and pressure drop with good flow distribution while adequately managing thermal stresses during operation. / Graduation date: 2013

The marked increase in surface-to-volume ratio associated with microscale devices for hemodialysis leads to problems with hemocompatibility and blood flow distribution that are more challenging to manage than those encountered at the conventional scale. In this work, stable surface modifications with pendant polyethylene oxide (PEO) chains were produced on polycarbonate microchannel and polyacrylonitrile membrane materials used in construction of microchannel hemodialyzer test articles. These coatings were evaluated in relation to protein repulsion, impact on urea permeability through the membrane, and impact on bubble retention through single-channel test articles. PEO layers were prepared by radiolytic grafting of PEO-PBD-PEO (PBD = polybutadiene) triblock copolymers to microchannel and membrane materials. Protein adsorption was detected by measurement of surface-bound enzyme activity following contact of uncoated and PEO-coated surfaces with ��-galactosidase. Protein adsorption was decreased on PEO-coated polycarbonate and polydimethyl siloxane (PDMS) materials by 80% when compared to the level recorded on uncoated materials. Protein adsorption on membrane materials was not decreased with PEO-PBD-PEO treatment; a PEI (polyethylene imide) layer exists on the AN69 ST membrane which is intended to trap heparin during membrane pre-treatment. It is still unclear how this PEI layer interacts with PEO-PBD-PEO. Neither the PEO-PBD-PEO triblocks nor the irradiation process was observed to have any effect on polyacrylonitrile membrane permeability to urea, nor did the presence of additional fibrinogen and bovine serum albumin (BSA) in the urea filtrate. The PEO-PBD-PEO treatment was not able to visibly reduce bubble retention during flow through single-channel polycarbonate test articles, however, the rough surfaces of the laser-etched polycarbonate microchannels may be causing this bubble retention. This surface treatment holds promise as a means for imparting safe, efficacious coatings to blood processing equipment that ensure good hemocompatibility and blood flow distribution, with no adverse effects on mass transfer. / Graduation date: 2013

This thesis deals with the development and calibrations of sensors to measure energetic neutral atoms (ENAs) at Mars, Venus, and the Earth. ENAs are formed in charge exchange processes between energetic, singly--charged ions and a cold neutral gas. Since ENAs can travel in long straight trajectories, unaffected by electric or magnetic fields, they can be used to remotely image plasma interactions with neutral atmospheres. ENA instrument techniques have matured over the last decade and ENA images of the Earth's ring current for example, have successfully been analyzed to extract ion distributions and characterize plasma flows and currents in the inner magnetosphere. Three different ENA sensors have been developed to image ENAs at Mars, Venus, and the Earth. Two of them, the nearly identical Neutral Particle imagers (NPIs) are on-board the Mars Express and Venus Express spacecraft as a part of the Analyzer of Space Plasmas and Energetic Atoms (ASPERA-3 and 4) instruments. The third is the Neutral Atom Detector Unit, NUADU, aboard the TC-2 spacecraft of the Double Star mission. The NPI design is based on a surface reflection technique to measure low energy (~0.3-60 keV) ENAs, while the NUADU instrument is based on a simple design with large geometrical factor and solid state detectors to measure high energy ENAs (~20-300 keV). The calibration approach of both NPI sensors were to define the detailed response, including properties such as the angular response function and efficiency of one reference sensor direction then find the relative response of the other sensor directions. Because of the simple geometry of the NUADU instrument, the calibration strategy involved simulations to find the cutoff energy, geometrical factor and angular response. The NUADU sensor head was then calibrated to find the response to particles of different mass and energy. The NPI sensor for the Mars Express mission revealed a so-called priority effect in the sensor that lowers the angular resolution at high detector bias. During the calibration of the Venus Express NPI sensor tests were made which showed that the priority effect is a result of low amplitude (noise) pulses generated in the detector system. The conclusion is that the effect is caused by capacitive couplings between different anode sectors of the sensor. The thresholds on the preamplifiers were set higher on the Venus Express NPI, which removed the priority effect. Two of the three ENA experiments, the Double Star NUADU instrument and the Mars Express NPI sensor, have successfully measured ENAs that are briefly described in the thesis. The first ENA measurements at Mars were performed with Mars Express. Initial results from the NPI include measurements of ENAs formed in the Martian magnetosheath and solar wind ENAs penetrating to the nightside of Mars. The first results from NUADU in Earth orbit show the expected ENA emissions from a storm time ring current. Also, together with the HENA instrument on the IMAGE spacecraft, NUADU have produced the first multi-point ENA image of the ring current.

In this thesis study, a least-squares finite element method (LSFEM) based conjugate heat transfer solver was developed. In the mentioned solver, fluid flow and heat transfer computations were performed separately. This means that the calculated velocity values in the flow calculation part were exported to the heat transfer part to be used in the convective part of the energy equation. Incompressible Navier-Stokes equations were used in the flow simulations. In conjugate heat transfer computations, it is required to calculate the heat transfer in both flow field and solid region. In this study, conjugate behavior was accomplished in a fully coupled manner, i.e., energy equation for fluid and solid regions was solved simultaneously and no boundary conditions were defined on the fluid-solid interface. To assure that the developed solver works properly, lid driven cavity flow, backward facing step flow and thermally driven cavity flow problems were simulated in three dimensions and the findings compared well with the available data from the literature. Couette flow and thermally driven cavity flow with conjugate heat transfer in two dimensions were modeled to further validate the solver. Finally, a microchannel conjugate heat transfer problem was simulated. In the flow solution part of the microchannel problem, conservation of mass was not achieved. This problem was expected since the LSFEM has problems related to mass conservation especially in high aspect ratio channels. In order to overcome the mentioned problem, weight of continuity equation was increased by multiplying it with a constant. Weighting worked for the microchannel problem and the mass conservation issue was resolved. Obtained results for microchannel heat transfer problem were in good agreement in general with the previous experimental and numerical works. In the first computations with the solver / quadrilateral and triangular elements for two dimensional problems, hexagonal and tetrahedron elements for three dimensional problems were tried. However, since only the quadrilateral and hexagonal elements gave satisfactory results, they were used in all the above mentioned simulations.

For the application of minichannel heat exchangers, it is necessary to have accurate design tools for predicting heat transfer and pressure drop. Until recently, this type of heat exchangers was not well studied, and in the scientific literature there were large discrepancies between results reported by different investigators. The present thesis aims to add to the knowledge of the fundamentals of single- and two-phase flow heat transfer and pressure drop in narrow channels, thereby aiding in the development of this new, interesting technology with the possibility of decreasing the size of electronics through better cooling, and of increasing the energy efficiency of thermal processes and thermodynamic cycles through enhanced heat transfer. A comprehensive experimental single-phase flow and saturated flow boiling heat transfer and pressure drop study has been carried out on vertical stainless steel tubes with inner diameters of 1.700, 1.224 and 0.826 mm, using R-134a as the test fluid. The heat transfer and pressure drop results were compared both to conventional correlations developed for larger diameter channels and to correlations developed specifically for microscale geometries. Contrary to many previous investigations, this study has shown that the test data agree well with single-phase heat transfer and friction factor correlations known to be accurate for larger channels, thus expanding their ranges to cover mini/microchannel geometries. The main part of the study concerns saturated flow boiling heat transfer and pressure drop. Tests with the same stainless steel tubes showed that the heat transfer is strongly dependent on heat flux, but only weakly dependent on mass flux and vapor fraction (up to the location of dryout). This behavior is usually taken to indicate a dominant influence of nucleate boiling, and indicates that the boiling mechanism is strongly related to that in nucleate boiling. The test data for boiling heat transfer was compared to several correlations from the literature, both for macro- and mini-channels. A new correlation for saturated flow boiling heat transfer of refrigerant R-134a correlation was obtained based on the present experimental data. This correlation predicts the presented data with a mean absolute deviation of 8%. The frictional pressure drop results were compared to both macro- and mini channel correlations available from the literature. The correlation suggested by Qu and Mudawar (2003) gave the best prediction to the frictional two-phase pressure drop within the studied ranges. A unique visualization study of saturated flow boiling characteristics in a vertical 1.332 mm inner diameter quartz tube, coated with a transparent heater has also been conducted. The complete evaporation process in a heated circular mini-channel has been studied visually in detail using high speed CCD camera. The study revealed the developments of the flow patterns and the behavior from bubble nucleation to the dry out of the liquid film. The bubble departure frequency, diameter, growth rate, and velocity were determined by analyzing the images. Finally, a flow pattern map for boiling flow in microchannels has been developed based on the test data. / QC 20100812

In this thesis, the vital cell functions performed by integral membrane proteins (IMPs) are briefly discussed. Such proteins are under-represented in most protein studies due to the hydrophobic nature of IMPs, which seriously complicate their solubilization, sample handling, preparation, separation and analysis. Conventional analytical techniques include for example matrix-assisted laser desorption/ionization mass spectrometry (MALDIMS), capillary electrophoresis (CE) and reversed phase high-performance liquid chromatography (RP-HPLC). Presented here are methods and protocols, which have been developed especially for IMP and hydrophobic peptide analysis, using the abovementioned techniques. The fluorinated organic solvent hexafluoroisopropanol (HFIP) has previously been shown beneficial as an additive for solubilization of hydrophobic analytes, which are poorly soluble in commonly used organic solvents or water. In Papers I-IV, HFIP is successfully exploited as solvent for the investigated IMPs and peptides. The simple fabrication and the focusing effect of a new structured MALDI target plate are presented in Paper I. This target plate contains concentrating sample spots, specifically designed to provide increased sensitivity for hydrophobic protein and peptide MALDI-MS analysis. When replacing a regular steel target with this new structured MALDI plate, more than a five-fold increase in average sensitivity is achieved for HFIP solubilized hydrophobic peptides. The full-length IMP bacteriorhodopsin (BR) and a cyanogen bromide digest thereof are used as model samples for the development of sample handling procedures in Paper II, and the peptides were used for evaluation of the MALDI-target plate in Paper I. Furthermore, the CE separation of the peptides, fractionation onto the structured MALDI plate and following MS analysis is presented in Paper III. Nine of the ten theoretical BR peptides were detected using this method. A protocol for the purification and analysis of chloroplast membrane proteins from the green macroalga Ulva lactuca has been described in Paper IV. The highest protein yield was achieved when proteins were extracted in HFIP, directly from the chloroplasts. The MALDI-MS analysis of samples with and without previous RP-HPLC fractionation revealed proteins with molecular weights ranging between 1 and 376 kDa. In Paper V, a closed-open-closed CE system is presented, containing an open microchannel for off-line MALDI detection. The electroosmotic flow and band broadening of this system has been evaluated. / QC 20100916

Microchannel heat exchangers present many advantages, such as reduced size, high thermal efficiency and low fluid inventory; and are increasingly being used for heat transfer in a wide variety of applications including heat pumps, automotive air conditioners and for cooling of electronics.However, the fundamentals of fluid flow and heat transfer in microscalegeometries are not yet fully understood. The aim of this thesis is to contribute to a better understanding of the underlying physical phenomena in single-phase and specially flow boiling heat transfer of refrigerants in small channels. For this purpose, well-characterized heat transfer experiments have been performed in uniformly heated, single, circular, vertical channels ranging from 0.64 to 1.70 mm in diameter and using R-134a, R-22 and R-245fa as working fluids. Furthermore, flow visualization tests have been carried out to clarify the relation between the two-phase flow behavior and the boiling heat transfer characteristics. Single-phase flow experiments with subcooled liquid refrigerant have confirmed that conventional macroscale theory on single-phase flow and heat transfer is valid for circular channels as small as 640μm in diameter. Through high-speed flow boiling visualization of R-134a under non adiabatic conditions seven flow patterns have been observed: isolated bubbly flow, confined bubbly flow, slug flow, churn flow, slug-annular flow, annular flow, and mist flow. Two-phase flow pattern observations are presented in the form of flow pattern maps. Annular-type flow patterns are dominant for vapor qualities above 0.2. Onset of nucleate boiling and subcooled flow boiling heat transfer of R-134a has been investigated. The wall superheat needed to initiate boiling was found as large as 18 ºC. The experimental heat transfer coefficients have been compared to predictions from subcooled flow boiling correlationsav ailable in the literature showing poor agreement. Saturated flow boiling heat transfer experiments have been performed with the 640 μm diameter test section. The heat transfer coefficient has been found to increase with heat flux and system pressure and not to change with vapor quality or mass flux when the quality is less than ∼0.5. For vapor qualities above this value, the heat transfer coefficient decreases with vapor quality. This deterioration of the heat transfer coefficient is believed to be caused by the occurrence of intermittent dryout in this vapor quality range. The experimental database, consisting of 1027 data points, has been compared against predictions from correlations available in the literature. The best results are obtained with the correlations by Liu and Winterton (1991) and by Bertsch et al. (2009). However, better design tools to correctly predict the flow boiling heat transfer coefficient in small geometries need to be developed. Dryout incipience and critical heat flux (CHF) have been investigated in detail. CHF data is compared to existing macro and microscale correlations. The comparison shows best agreement with the classical Katto and Ohno (1984) correlation, developed for conventional large tubes. / QC 20101101

En el presente trabajo, utilizamos técnicas de microfabricación, simulaciones numéricas, experimentos de electrofisiología para explorar la viabilidad en me- jorar la interface ordenador-neurona a través de microcanales, y la biofísica para la generación de señales en los dispositivos con microcanales. También demos- tramos que los microcanales pueden ser usados como una técnica prometedora con alto rendimiento en el muestreo automático de canales iónicos a nivel subce- lular. Finalmente, se ha diseñado, fabricado y probado el micropozo-microcanal como modificación adicional a los arreglos de multielectrodos, permitiendo una alta ganancia en la relación señal/ ruido (en inglés Signal to Noise Ratio SNR), y el registro de múltiples-lugares en poblaciones de baja densidad de redes neu- ronales del hipocampo in vitro. Primero, demostramos que son de alto rendimiento los microcanales de bajo costo con interface neurona-electrodo, para el registro extracelular de la activi- dad neuronal con baja complexidad, por periodos estables de larga duración y con alta ganancia SNR. En seguida, se realiza un estudio mediante experimentos y simulaciones nu- méricas de la biofísica para la generación de las señales obtenidas de los dispositi- vos con microcanales. Basados en los resultados, racionalizamos y demostramos como es que la longitud del canal (siendo 200 μm) y la sección transversal del microcanal (siendo 12 μm2) canaliza a los potenciales de acción para estar dentro del rango de milivolts. A pesar del bajo grado de complexidad envuelto en la fabricación y aplicación, los dispositivos con microcanales otorgan una sola media de valor SNR de 101 76, lo cual es favorablemente comparable con la SNR que se obtiene de desarrollos recientes que emplean electrodos curados con CNT y Si-NWFETs. Más aún, nosotros demostramos que el microcanal es una técnica promete- dora para el alto rendimiento del muestro automático de canales iónicos a nivel subcelular: (1) Información experimental y simulaciones numéricas sugieren que las señales registradas sólo afectan los parches membranales localizados dentro del microcanal o alrededor de 100 μm de las entradas del microcanal. (2) La transferencia de masa de los componentes químicos en los microcanales fue ana- lizada por experimentos y simulaciones FEM. Los resultados muestran que los microcanales que contienen glía y tejido neuronal pueden funcionar como barre- ra de fluido/química. Los componentes químicos pueden ser solamente aplicados a diferentes compartimentos a nivel subcelular. Finalmente, basado en simulaciones numéricas y resultados experimentales, se propone que del micropozo-microcanal, obtenido de la modificación de MEA (MWMC-MEA), la longitud óptima del canal debe ser 0,3 mm y la posición 1 óptima del electrodo intracanal, hacia la entrada más cercana del microcanal, debe ser 0,1 mm. Nosotros fabricamos un prototipo de MWMC-MEA, cuyo hoyo pasante sobre las películas de Polydimethylsiloxane (PDMS) fue microtrabajado a través de la técnica de grabados reactivos de plasma de iones. La baja densidad del cultivo (57 neuronas /mm2) en el MWMC-MEAs permitió que las neuronas vivieran al menos 14 días, con lo que la señal neuronal con la máxima SNR obtenida fue de 142. 2 / In this present work, we used microfabrication techniques, numerical simulations, electrophysiological experiments to explore the feasibility of enhancing neuron-computer interfaces with microchannels and the biophysics of the signal generation in microchannel devices. We also demonstrate the microchannel can be used as a promising technique for high-throughput automatic ion-channel screening at subcellular level. Finally, a microwell-microchannel enhanced multielectrode array allowing high signal-to-noise ratio (SNR), multi-site recording from the low-density hippocampal neural network in vitro was designed, fabricated and tested. First, we demonstrate using microchannels as a low-cost neuron-electrode interface to support low-complexity, long-term-stable, high SNR extracellular recording of neural activity, with high-throughput potential. Next, the biophysics of the signal generation of microchannel devices was studied by experiments and numerical simulations. Based on the results, we demonstrate and rationalize how channels with a length of 200 μm and channel cross section of 12 μm2 yielded spike sizes in the millivolt range. Despite the low degree of complexity involved in their fabrication and use, microchannel devices provided a single-unit mean SNR of 101 76, which compares favourably with the SNR obtained from recent developments employing CNT-coated electrodes and Si-NWFETs. Moreover, we further demonstrate that the microchannel is a promising technique for high-throughput automatic ion-channel screening at subcellular level: (1) Experimental data and numerical simulations suggest that the recorded signals are only affected by the membrane patches located inside the microchannel or within 100 μm to the microchannel entrances. (2) The mass transfer of chemical compounds in microchannels was analyzed by experiments and FEM simulations. The results show that the microchannel threaded by glial and neural tissue can function as fluid/chemical barrier. Thus chemical compounds can be applied to different subcellular compartments exclusively. Finally, a microwell-microchannel enhanced MEA (MWMC-MEA), with the optimal channel length of 0.3 mm and the optimal intrachannel electrode position of 0.1 mm to the nearest channel entrance, was proposed based on numerical simulation and experiment results. We fabricated a prototype of the MWMCMEA, whose through-hole feature of Polydimethylsiloxane film (PDMS) was micromachined by reactive-ion etching. The low-density culture (57 neurons/mm2) were survived on the MWMC-MEAs for at least 14 days, from which the neuronal signal with the maximum SNR of 142 was obtained.

Doubling transistor count for every two years in a computer chip, transmitter and receiver (T/R) module of a phased-array antenna that demands higher power with smaller dimensions are all results of miniaturization in electronics packaging. These technologies nowadays depend on improvement of reliable high performance heat sink to perform in narrower volumes. Employing microchannels or open cell metal foam heat sinks are two recently developing promising methods of cooling high heat fluxes. Although recent studies especially on microchannels can give a rough estimate on performances of these two methods, since using metal foams as heat sinks is still needed further studies, a direct experimental comparison of heat exchanger performances of these two techniques is still needed especially for thermal design engineers to decide the method of cooling. For this study, microchannels with channel widths of 300 &micro / m, 420 &micro / m, 500 &micro / m and 900 &micro / m were produced. Also, 92% porous 10, 20 and 40 ppi 6101-T6 open cell aluminum metal foams with compression factors 1,2, and 3 that have the same finned volume of microchannels with exactly same dimensions were used to manufacture heat sinks with method of vacuum brazing. They all have tested under same conditions with volumetric flow rate ranging from 0,167 l/min to 1,33 l/min and 60 W of heat power. Channel height was 4 mm for all heat sinks and distilled water used as cooling fluid. After experiments, pressure drops and thermal resistances were compared with tabulated and graphical forms. Also, the use of metal foam and microchannel heat sinks were highlighted with their advantages and disadvantages for future projects.