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Evaporation is used in the dairy industry to reduce the production costs of powder production (including milk powder) as it is more energy efficient to remove water by evaporation than by drying. There are significant economic reasons why gaining a greater understanding of the complex interactions occurring between the liquid and vapour phases in evaporators is advantageous. The multiphase flows in industrial dairy falling film evaporators were studied. Several computational fluid dynamic (CFD) models were created using Ansys CFX 10. Two case studies were chosen. The first case involved modelling the dispersed droplets that require separation from the water vapour evaporated from the feed of the evaporator. The CFD results were able to show that fouling was not caused by a lack of separation. The predicted separation agreed with experimental measurements. The atomisation process was found to be critical in the prediction of the separation. The atomisation process is not well understood and introduced the greatest error to the model. A plug flow assumption is currently used as a basis for the design the separators. The CFD solutions found no validity to this assumption. The second case study aimed to model and solve the distribution of the feed into the heat transfer tubes at the top of the falling film evaporators. The goal of this study was to be able to accurately predict wetting of the tubes. The volume of fluid (VOF) method using the continuum surface force method (CSF) to account for surface tension was chosen to model the system. The poor curvature estimate of the CSF method was found to produce parasitic currents that limited the stability of the solutions. Small VOF timesteps prevented the solver from diverging and the parasitic currents would oscillate the interface around the correct location. The small timesteps required significantly more computational power than was available and the model for the distribution process could not be solved. The CSF VOF method showed considerable promise, particularly because it can predict free surface topography without user input. There are still questions about numerical creeping of films, but the method was able to correctly predict several different surface tension and contact angle dominated film flows expected to be needed to accurately model the distribution of the falling film evaporator. Validated solutions of jet, meniscus, sessile, "overfall" and 3-D weir models were obtained and these agreed with published results in literature. A 2-D weir solution showed qualitative agreement with the expected form of the film. A 2-D hydraulic jump model without surface tension was created and agreed with experimental work in the literature to within 22%. The 3-D hydraulic jump solution only showed partial agreement with published experimental, the solutions were not mesh independent and not well converged so few conclusions can be drawn. The solutions of a rivulet model showed qualitative similarities with experimental work. The predicted wetting rate did not agree with values in the published literature because the spatial domain modelled was believed to be too narrow. An extended model of rivulet flow agreed with the idealised rivulet profile in literature and the predicted wetting rate agreed with some of the published literature. Again the solutions were not mesh independent so few conclusions can be confirmed.

The objective of this study is to understand the effect of surface roughness of the Cu substrate on the wetting of molten solder alloys. Eutectic Sn-Pb, pure Sn and eutectic Sn-Cu solder alloys and Cu substrates with different surface finish viz., highly polished surface, polished surface and unpolished surface were used in this work. Highly polished surface was prepared in Metallography lab, University of Kentucky while other two substrates were obtained from a vendor. Surface roughness properties of each substrate were measured using an optical profilometer. Highly polished surface was found to be of least surface roughness, while unpolished surface was the roughest. Hot-stage microscopy experiments were conducted to promote the wetting behavior of each solder on different Cu substrates. Still digital images extracted from the movies of spreading recorded during hot-stage experiments were analyzed and data was used to generate the plots of relative area of spread of solder versus time. The study of plots showed that surface roughness of the Cu substrate had major influence on spreading characteristics of eutectic Sn-Pb solder alloy. Solder showed better spreading on the Cu substrate with least surface roughness than the substrates with more roughness. No significant influence of surface roughness was observed on the wetting behavior of lead free solders (pure Sn and eutectic Sn-Cu).

The ability to effectively join magnesium alloys to steel will facilitate increased application and use of Mg alloys in the automotive and aerospace industries where joining Mg alloys to steel in order to achieve light weight, versatile and tailored properties in one composite part is highly desirable. The current thesis details (i) the development of a laser brazing technology for joining Mg alloy-interlayer-steel dissimilar metal combinations, (ii) thermochemical analysis of phases formed at the interface of a Mg alloy-steel joint during laser brazing, (iii) the bonding mechanisms in the Mg alloy-interlayer-steel joints using Al-12Si, Ni, and Sn interlayers, and (iv) the mechanism responsible for wetting of steel by molten Mg alloy during the laser brazing. Firstly, a diode laser brazing procedure has been developed for joining AZ31B-H24 Mg alloy sheet to aluminum coated steel sheet using a AZ92 Mg alloy filler wire. The results of this study suggest that feasibility of this process depends strongly on the pre-existing Al-12Si coating layer on the steel sheet that promotes wetting of the AZ92 Mg alloy filler alloy as well as formation of a layer of θ-Fe(Al,Si)3 interetallic compound along the fusion zone-steel interface. The average joint efficiency was 29% with respect to the AZ31B-H24 Mg alloy base metal. Failure occurred when cracks propagated along the intermetallic layer. Secondly, to predict early stage phase formation in the Mg alloy-interlayer-steel system during the laser brazing process, the thermodynamic stability of precipitated phases at the Mg alloy-Ni-steel interface during laser brazing has been evaluated using FactSage thermochemical software. Assuming local chemical equilibrium at the interface, the chemical activity-temperature-composition relationships of intermetallic compounds that might form in the AZ92 magnesium alloy-Ni-steel system in the temperature range of 600-1100 °C were estimated. The addition of a Ni interlayer between the steel and the Mg brazing alloy was predicted to result in the formation of the AlNi, Mg2Ni, and Al3Ni2 intermetallic compounds at the interface depending on the local maximum temperature. This was confirmed experimentally by laser brazing of AZ31B-H24 magnesium alloy and steel sheet with a micro-layer of electro-deposited Ni using AZ92 magnesium alloy filler wire. Bonding between the magnesium alloy and the steel was facilitated by the formation of a transition layer composed of a solid solution of Ni in Fe on the steel followed by a layer of α-Mg + Mg2Ni eutectic. A band of AlNi with different morphologies also formed along the fusion zone-steel interface, but was not directly responsible for bonding. The average joint efficiency was 56.5% with respect to the AZ31B-H24 Mg alloy base metal and 94.8% higher than that of laser brazed joint using Al-12Si interlayer. Thirdly, to study a low melting point temperature interlayer element, the brazeability of AZ31B-H24 magnesium alloy sheet to Sn-coated steel sheet has been investigated. All tensile-shear specimens fractured in the steel base metal well away from the brazed joint. The results showed that while the Sn coating promoted good wetting between the molten filler alloy and the steel sheet, it did not play a role in forming the final bond. Its primary function appeared to be in maintaining a clean, oxide-free steel surface until the molten Mg filler alloy could come in direct contact with the steel surface. Bonding between the magnesium alloy and the steel was facilitated by the formation of two nano-scale transition layers composed of Fe(Al) solid solution on the steel followed by a layer of Al8Mn5 phase on top of Fe(Al) in the fusion zone along the interface. High resolution-TEM analysis showed that an orientation relationships (OR) with low angle of rotation of the matching planes and low interplanar mismatch existed at the Fe(Al)-Al8(Mn,Fe)5 interface. This was found to be responsible for the low interfacial energy density, good wetting and strong interfacial bond observed in this complex dissimilar metal system. Finally, wetting has been characterized by measuring the contact angles of AZ92 Mg alloy on Ni electro-plated steel as a function of measured peak temperature reached during laser heating. Reactions between molten Mg and Ni led to a contact angle of about 86º in the peak temperature range of 618-750 ºC (denoted as Mode I) and a dramatic decrease to about 46º in the temperature range of 824-1020 ºC (denoted as Mode II). Scanning and transmission electron microscopy (SEM and TEM) indicated that AlNi + Mg2Ni reaction products were produced between Mg and steel (Mg-AlNi-Mg2Ni-Ni-Fe) in Mode I, and just AlNi between Mg and steel (Mg-AlNi-Fe) in Mode II. From high resolution TEM analysis, the measured interplanar mismatches for different formed interfaces in Modes I and II were 17% {Mg-AlNi}-104% {AlNi-Mg2Ni}-114% {Mg2Ni-Ni} and 18% {Mg-AlNi}-5% {AlNi-Fe}, respectively. Therefore, it is suggested that the poor wettability in Mode I was caused by the existence of Mg2Ni since AlNi was the immediate layer contacting molten Mg in both Modes I and II and the presence of Mg2Ni increases the interfacial strain energy of the system. This study has clearly demonstrated that the lattice mismatching at the interfaces between reaction product(s) and substrate, which are not in direct contact with the liquid, can greatly influence the wetting of the liquid.

As energy certification programs and mandatory governmental building codes demand better building energy performance, the development of durable, highly insulated wall systems has become a top priority. Wood framed walls are the most common form of residential wall in North America and the materials used are vulnerable to moisture damage. This damage typically occurs first at the wall sheathing in the form of mould, fungal growth and rot. Increased thermal resistance can lead to two potential issues related to moisture durability: 1) increased potential for air leakage condensation at the sheathing and 2) decreased ability of the wall to dry after a wetting event. A natural exposure experimental study was performed at the University of Waterloo’s BEGHUT test facility to evaluate the hygrothermal performance of exterior insulated wall systems utilizing 3 different insulation types. These walls had approximately 2/3 of their total thermal resistance interior to the sheathing and 1/3 exterior to the sheathing. These walls were compared to a standard construction wall and a highly insulated double stud wall system. The test walls were evaluated during as-built conditions and during imposed wetting conditions. Moisture was introduced into the walls in two phases. The air injection wetting phase was designed to evaluate air leakage condensation potential during winter conditions, and the wetting mat wetting phase simulated an exterior rain leak and was used to evaluate the drying potential of the test walls. Hourly temperature, relative humidity and moisture content measurements were taken at multiple locations within each test wall. This data was analyzed to determine the air leakage condensation potential and the drying capability of each test wall. Results showed that the effective thermal resistance of the polyisocyanurate (PIC) insulation was significantly less than its nominal R-value rating under cold and moderate temperature conditions, and slightly higher under hot conditions. The effective thermal resistance of the extruded polystyrene (XPS) insulation was slightly less than its rated value under cold and moderate temperature conditions and significantly less under hot conditions. The rockwool (RW) insulation performed slightly above its rated thermal resistance under cold and moderate conditions and slightly less under hot conditions. Results also showed that only the double stud wall was vulnerable to winter-time interstitial condensation during the as-built (air-sealed) condition. This was a result of the hygroscopic nature of the cellulose insulation and a large temperature gradient across the insulation cavity. During the air leakage wetting phase, all of the exterior insulated walls showed a significantly decreased risk of air leakage condensation compared to the Datum and Double stud walls. During and following the wetting mat wetting phase, the PIC and XPS walls showed significantly reduced drying capability, while the RW wall showed a small reduction in drying capacity compared to the Datum and Double stud walls. It was concluded that adding insulation exterior to the wall sheathing can be an effective method to minimize air leakage condensation. The minimum ratio of exterior to interior insulation, however, must be suitable for the local climate and interior humidity conditions. Exterior insulation materials with low vapour permeability can significantly reduce the drying capacity of a wall system, but may be appropriate where exterior solar vapour drive is a concern or sufficient drying to the interior is available. Exterior insulation materials with high vapour permeability facilitate drying to the exterior and dry nearly as well as wall systems with no exterior insulation.

This thesis documents the work undertaken to investigate and improve the theoretical and practical requirements for two-dimensional hydrodynamic modelling of coastal and estuarine areas, in particular to the inter-related aspects of: - wetting and drying of relatively large intertidal areas, and - the influences of waves on both current generation and variations in mean water level. The work outlined in this thesis began as a result of a perceived lack of understanding and confidence in the application of finite element models to coastal and estuarine situations. In response to this observation an investigation into the modelling parameters, particularly those that affect model performance during the simulation of wetting and drying, was undertaken. This initial investigation into the effect of these parameters upon model performance forms the first component of this study. Testing was performed to provide a quantitative assessment of the effect of these parameters upon model performance. The initial tests were simple examples designed to investigate the behaviour of a single specific parameter. Subsequent tests were more complex and assessed the combinations of various parameter selections. Once the model was shown to accurately simulate the movement of waters in a coastal and estuarine environment, wave forces were incorporated. The aim of the second component of the study was to modify the hydrodynamic model to predict the net current and water levels attributable to the influences of waves. Tests examined the effects of the application of wave induced forces in a range of applications, including the simple case of a uniform beach, comparisons to a physical model, and an example from a real coastline. The final outcome of this study is the development of a modelling tool that can accurately represent the forces of tides, winds and waves upon water movement in a shallow coastal and/or estuarine region. Furthermore, the qualitative and quantitative assessments of parameters that affect the performance of the model provide greater confidence in model results and better understanding of the applicability and limits of the modelling technique. Principal outcomes of the study are: - an improved understanding of the parameters which influence the behaviour of hydrodynamic models; - a better understanding of the applicability and limits of the modelling technique; and - an enhanced software system based on an existing modelling software system which is applicable to studies that require simulation of the combined forces of tides, winds and waves.

Thesis (Ph. D.)--State University of New York at Binghamton, Mechanical Engineering Department, 2005. / Includes bibliographical references (leaves 149-155).

Thesis (Ph. D.)--University of Texas at Austin, 2007. / Vita. Includes bibliographical references.

Thesis (Ph. D.)--Auburn University, 2008. / Abstract. Vita. Includes bibliographical references.

Thèse (D.Eng.) -- Université du Québec à Chicoutimi, 2006. / La p. de t. porte en outre: Thèse présentée à l'Université du Québec à Chicoutimi pour l'obtention du doctorat en ingénierie. CaQCU Bibliogr.: f. 130-147. Document électronique également accessible en format PDF. CaQCU