Controlling and predicting rupture and dewetting of quiescent thin water films, hundreds of microns thick, was studied experimentally. Wax, polycarbonate, steel and aluminium surfaces were immersed in water; the water level was lowered to form thin films above the surfaces. Spontaneous film rupture only occurred on wax, a low-energy surface. Films ruptured at the edges of the other—high-energy—surfaces. Increased surface roughness decreased chances of rupture and dewetting in the film. Introducing large wax or steel protrusions (on the order of millimetres) on smooth surfaces showed films rupturing above the protrusions and adhering to them; further thinning caused rupture and dewetting away from the protrusions. Entrapped air bubbles, injected through the surface and into the film, ruptured as they breached the film surface to form stable holes in the film if it was sufficiently thin. Entrapped air was the best means of rupturing films on all surfaces.

Controlling and predicting rupture and dewetting of quiescent thin water films, hundreds of microns thick, was studied experimentally. Wax, polycarbonate, steel and aluminium surfaces were immersed in water; the water level was lowered to form thin films above the surfaces. Spontaneous film rupture only occurred on wax, a low-energy surface. Films ruptured at the edges of the other—high-energy—surfaces. Increased surface roughness decreased chances of rupture and dewetting in the film. Introducing large wax or steel protrusions (on the order of millimetres) on smooth surfaces showed films rupturing above the protrusions and adhering to them; further thinning caused rupture and dewetting away from the protrusions. Entrapped air bubbles, injected through the surface and into the film, ruptured as they breached the film surface to form stable holes in the film if it was sufficiently thin. Entrapped air was the best means of rupturing films on all surfaces.

Water infiltration into the unsaturated zone especially in a shallow water table environment is affected by air compression ahead of the wetting front and air counterflow. Neglecting air compression in infiltration modeling can overestimate infiltration and infiltration rates, whereas not accounting for air counterflow can underestimate infiltration and infiltration rates due to unrealistic buildup of air pressure resistance ahead of the wetting front. A method, derived on the basis of the Green and Ampt (1911) infiltration model, is introduced to simulate air compression and air counterflow during infiltration into a shallow water table. The method retains the simplicity of the Green and Ampt (1911) model but adds the air pressure resistance term ahead of the wetting front. Infiltration equations are derived on the basis of the Green and Ampt (1911) and Sabeh’s (2004) infiltration model which accounts for air compression and air counterflow. The difference between this method and Sabeh’s (2004) model is that air counterflow, air compression, and infiltration are decoupled and updated with each wetting front increment whereas Sabeh’s (2004) method uses time step as a decoupling mechanism. Air compression ahead of the wetting front is predicted using the perfect gas law. Laboratory experiments showed that the introduced method is reasonably accurate when modeling cumulative infiltration values. Results of laboratory experiments were compared to results of the modeled infiltration methods: original Green and Ampt (1911) model and Green and Ampt with air compression and counterflow. The advantage of this new method is its simplicity. The new method uses parameters that are generally needed for modeling infiltration with the Green and Ampt (1911) approach. Disadvantages of the model are assumptions of the uniform water content and the uniform pressure. Another shortcoming of the model is that it does not account for air compression and air counterflow prior to ponding. Laboratory experiments described in this work and a proposed model can be further used for modeling and studying infiltration with air effects. In addition, this work can be of use to someone studying irrigation techniques of rice or other crops.

Omniphobic surfaces, which repel polar and non-polar liquids alike, have proven of value in a myriad of applications ranging from piping networks, textiles, food and electronics packaging, and underwater drag reduction. A limitation of currently employed omniphobic surfaces is their reliance on perfluorinated coatings/chemicals, increasing cost and environmental impact and preventing applications in harsh environments. Thus, there is a keen interest in rendering conventional materials, such as hydrocarbon-based plastics, omniphobic by micro/ nanotexturing rather than via chemical makeup, with notable success having been achieved for silica surfaces with doubly reentrant pillars (DRPs). We discovered a critical limitation of DRPs – they catastrophically lose superomniphobicity in the presence of localized physical damages/defects or on immersion in wetting liquids. In response, we pioneered bio-inspired gas-entrapping microtextured surfaces (GEMS) architecture composed of doubly reentrant cavities (DRCs). DRCs are capable of robustly entrapping air when brought into contact with liquid droplets or on immersion, which prevents catastrophic wetting transitions even in the presence of localized structural damage/defects. This dissertation presents our multifaceted research on DRCs via custom-built pressure cells, confocal laser scanning microscopy, environmental scanning electron microscopy, contact angle goniometry, high-speed imaging, and upright optical microscopy. Specific accomplishments detailed in this thesis include: (i) the microfabrication protocols for silica GEMS developed at KAUST; (ii) the characterization of GEMS’ omniphobicity via apparent contact angles and immersion; (iii) the demonstration of ~ 1000,000,000% delays in wetting transitions in DRCs compared to those in simple cavities (SCs) under hexadecane; (iv) a proposal for immersion of surfaces as a criterion for assessing their omniphobicity in addition to apparent contact angles; (v) effects of surface chemistry, hydrostatic pressure, and cavity dimensions on Cassie-to-Wenzel transitions in DRCs and SCs; (vi) the demonstration of “breathing” (liquid-vapor) interfaces in GEMS under fluctuating hydrostatic pressures; and (vii) the demonstration of directional wetting transitions in DRCs (or cavities in general) arranged in one- and two-dimensional lattices. The last chapter in the thesis presents future research directions such as breathing surfaces capable of preempting vapor condensation and gas replenishment.

The presence of gas in engine liquid cooling systems can have severe consequences for engine efficiency and life. The presence of stagnant, trapped gases will result in cooling system hotspots, causing gallery wall degradation through thermal stresses, fatigue and eventual cracking. The presence of entrained, transient gases in the coolant flow will act to reduce its bulk thermal properties and the performance of the system s coolant pump; critically the liquid flow rate, which will severely affect heat transfer throughout the engine and its ancillaries. The hold-up of gas in the pump s impeller may cause the dynamic seal to run dry, without lubrication or cooling. This poses both an immediate failure threat should the seal overheat and rubber components melt and a long term failure threat from intermittent quench cooling, which causes deposit formation on sealing faces acting to abrade and reduce seal quality. Bubbles in the coolant flow will also act as nucleation sites for cavitation growth. This will reduce the Net Positive Suction Head available (NPSHA) in the coolant flow, exacerbating cavitation and its damaging effects in locations such as the cylinder cooling liners and the pump s impeller. This thesis has analysed the occurrence of trapped gas (air) during the coolant filling process, its behaviour and break-up at engine start, the two-phase character of the coolant flow these processes generate and the effects it has on coolant pump performance. Optical and parametric data has been acquired in each of these studies, providing an understanding of the physical processes occurring, key variables and a means of validating numerical (CFD) code of integral processes. From the fundamental understanding each study has provided design rules, guidelines and validated tools have been developed, helping cooling system designers minimise the occurrence of trapped air during coolant filling, promote its breakup at engine start and to minimise its negative effects in the centrifugal coolant pump. It was concluded that whilst ideally the prevention of cooling system gases should be achieved at source, they are often unavoidable. This is due to the cost implications of finding a cylinder head gasket capable of completely sealing in-cylinder combustion pressures, the regular use of nucleate boiling regimes for engine cooling and the need to design cooling channel geometries to cool engine components and not necessarily to avoid fill entrapped air. Using the provided rules and models, it may be ensured stagnant air is minimised at source and avoided whilst an engine is running. However, to abate the effects of entrained gases in the coolant pump through redesign is undesirable due to the negative effects such changes have on a pump s efficiency and cavitation characteristics. It was concluded that the best solution to entrained gases, unavoidable at source, is to remove them from the coolant flow entirely using phase separation device(s).

Drop impact is a canonical problem in fluid mechanics, with numerous applications in industrial as well as natural phenomena. The extremely simple initial configuration of the experiment can produce a very large variety of fast and complex dynamics. Scientific progress was made in parallel with major improvements in imaging and computational technologies. Most recently, high-speed imaging video cameras have opened the exploration of new phenomena occurring at the micro-second scale, and parallel computing allowed realistic direct numerical simulations of drop impacts. We combine these tools to bring a new understanding of two fundamental aspects of drop impacts: splashing and air entrapment. The early dynamics of a drop impacting on a liquid pool at high velocity produces an ejecta sheet, emerging horizontally in the neck between the drop and the pool. We show how the interaction of this thin liquid sheet with the air, the drop or the pool, can produce micro-droplets and bubble rings. Then we detail how the breakup of the air film stretched between the drop and the pool for lower impact velocities can produce a myriad of micro-bubbles.

Am Anfang des Entwicklungsprozesses eines Gussbauteils für die Automobilbranche steht klassischerweise die konstruktive Ausarbeitung und die Auslegung auf Zielgrößen, wie Festigkeit, Steifigkeit bzw. die Erfüllung der Crashlasten. Im nächsten Entwicklungsschritt wird, oftmals in Zusammenarbeit mit externen Lieferanten, das Werkzeugkonzept entwickelt und die Herstellbarkeit mit Hilfe von Gießsimulationen abgesichert. Bei der Fertigung verursachen streuende Prozessgrößen, wie etwa Geschwindigkeits- oder Temperaturniveaus, Schwankungen in der Leistungsfähigkeit des Endprodukts (z. B. lokale Bruchdehnung oder Zugfestigkeit). Maßnahmen zur Erhöhung der Prozessstabilität und zur Reduktion des Verschleißes konzentrieren sich oftmals auf die erfahrungsbasierte Verbesserung des Fertigungsprozesses und Anpassungen des Anguss- und Überlaufsystems. Größere Änderungen der Bauteilgeometrie sind häufig aus zeitlichen Gründen nicht mehr möglich. Das Ziel dieser Arbeit ist es daher, optimierte modularisierte Grundgeometrien, wie Rippen oder Umlenkungen, mit Hilfe von numerischen Formoptimierungen zu entwickeln, um diese schon von Anfang an in der Bauteilentwicklung zu berücksichtigen. Als Zielfunktionen dienen strömungs- und strukturmechanische Kenngrößen, um einerseits verschleißfördernde Mechanismen und füllungsbedingte Defekte zu reduzieren und andererseits die Beanspruchbarkeit zu erhöhen. Bei den Untersuchungen wird zusätzlich die Robustheit des Ergebnisses analysiert, um Verbesserungspotenziale auch bei streuenden Randbedingungen realisieren zu können. / The virtual development process of an automotive casting part usually begins with classical design tasks and analyses of material strength, stiffness and crash load cases. In the next step, often in cooperation with external suppliers, the tooling concept is developed and casting simulations are used to ensure manufacturability. During manufacturing there is a scatter in process parameters, such as flow velocity or temperature levels, which in turn cause a scatter in the performance of the final product (e.g. local elongation at fracture or ultimate tensile strength). Means to increase process stability and yield are often limited to knowledge-based improvements of the manufacturing process parameters and adaptations of the gating and overflow system. Major changes to the part geometry are usually no longer possible due to project time constraints. Therefore it is the goal of this thesis to optimize modularized basic geometries, like ribs or bends, by using numerical shape optimizations and employ them right from the beginning of the part development process. For the objective functions of the optimizations the disciplines of fluid dynamic filling and the resulting structural behaviour are considered. In addition, the resulting shape is analyzed with regards to robustness towards scatter in manufacturing operating conditions. By using these new modularized geometries the overall robustness of the final product is expected to be increased.

Am Anfang des Entwicklungsprozesses eines Gussbauteils für die Automobilbranche steht klassischerweise die konstruktive Ausarbeitung und die Auslegung auf Zielgrößen, wie Festigkeit, Steifigkeit bzw. die Erfüllung der Crashlasten. Im nächsten Entwicklungsschritt wird, oftmals in Zusammenarbeit mit externen Lieferanten, das Werkzeugkonzept entwickelt und die Herstellbarkeit mit Hilfe von Gießsimulationen abgesichert. Bei der Fertigung verursachen streuende Prozessgrößen, wie etwa Geschwindigkeits- oder Temperaturniveaus, Schwankungen in der Leistungsfähigkeit des Endprodukts (z. B. lokale Bruchdehnung oder Zugfestigkeit). Maßnahmen zur Erhöhung der Prozessstabilität und zur Reduktion des Verschleißes konzentrieren sich oftmals auf die erfahrungsbasierte Verbesserung des Fertigungsprozesses und Anpassungen des Anguss- und Überlaufsystems. Größere Änderungen der Bauteilgeometrie sind häufig aus zeitlichen Gründen nicht mehr möglich. Das Ziel dieser Arbeit ist es daher, optimierte modularisierte Grundgeometrien, wie Rippen oder Umlenkungen, mit Hilfe von numerischen Formoptimierungen zu entwickeln, um diese schon von Anfang an in der Bauteilentwicklung zu berücksichtigen. Als Zielfunktionen dienen strömungs- und strukturmechanische Kenngrößen, um einerseits verschleißfördernde Mechanismen und füllungsbedingte Defekte zu reduzieren und andererseits die Beanspruchbarkeit zu erhöhen. Bei den Untersuchungen wird zusätzlich die Robustheit des Ergebnisses analysiert, um Verbesserungspotenziale auch bei streuenden Randbedingungen realisieren zu können.:1 Einleitung 1.1 Motivation und Problemstellung 1.2 Zielsetzung und Vorgehensweise 1.3 Stand von Wissenschaft und Technik 2 Grundlagen 2.1 Leichtmetallgussbauteile im Automobil 2.2 Geometrische Gestaltung von Gussbauteilen 2.3 Modellierung gießtechnischer Fertigungsverfahren 2.4 Strukturmechanische Modellierung von Gussbauteilen 2.5 Numerische Optimierung 3 Modellaufbau und -analyse 3.1 Geometrische Entwurfsmodelle 3.2 Strömungsmodellbildung zur Abbildung der Fertigungseinflüsse 3.3 Strukturberechnungsmodell unter Berücksichtigung materieller Defekte 4 Optimierung der Umlenkung 4.1 Optimierungsstrategie und -prozesskette 4.2 Zielfunktionen 4.3 Optimierung mit Entwurfsmodell I 4.4 Optimierung mit Entwurfsmodell II 4.5 Diskussion der Ergebnisse 5 Optimierung der Rippe 5.1 Optimierungsstrategie und -prozesskette 5.2 Ziel- und Restriktionsfunktionen 5.3 Multidisziplinäre Optimierung 5.4 Diskussion der Ergebnisse 6 Zusammenfassung 7 Ausblick Anhang Abkürzungs- und Symbolverzeichnis Literatur- und Quellenverzeichnis / The virtual development process of an automotive casting part usually begins with classical design tasks and analyses of material strength, stiffness and crash load cases. In the next step, often in cooperation with external suppliers, the tooling concept is developed and casting simulations are used to ensure manufacturability. During manufacturing there is a scatter in process parameters, such as flow velocity or temperature levels, which in turn cause a scatter in the performance of the final product (e.g. local elongation at fracture or ultimate tensile strength). Means to increase process stability and yield are often limited to knowledge-based improvements of the manufacturing process parameters and adaptations of the gating and overflow system. Major changes to the part geometry are usually no longer possible due to project time constraints. Therefore it is the goal of this thesis to optimize modularized basic geometries, like ribs or bends, by using numerical shape optimizations and employ them right from the beginning of the part development process. For the objective functions of the optimizations the disciplines of fluid dynamic filling and the resulting structural behaviour are considered. In addition, the resulting shape is analyzed with regards to robustness towards scatter in manufacturing operating conditions. By using these new modularized geometries the overall robustness of the final product is expected to be increased.:1 Einleitung 1.1 Motivation und Problemstellung 1.2 Zielsetzung und Vorgehensweise 1.3 Stand von Wissenschaft und Technik 2 Grundlagen 2.1 Leichtmetallgussbauteile im Automobil 2.2 Geometrische Gestaltung von Gussbauteilen 2.3 Modellierung gießtechnischer Fertigungsverfahren 2.4 Strukturmechanische Modellierung von Gussbauteilen 2.5 Numerische Optimierung 3 Modellaufbau und -analyse 3.1 Geometrische Entwurfsmodelle 3.2 Strömungsmodellbildung zur Abbildung der Fertigungseinflüsse 3.3 Strukturberechnungsmodell unter Berücksichtigung materieller Defekte 4 Optimierung der Umlenkung 4.1 Optimierungsstrategie und -prozesskette 4.2 Zielfunktionen 4.3 Optimierung mit Entwurfsmodell I 4.4 Optimierung mit Entwurfsmodell II 4.5 Diskussion der Ergebnisse 5 Optimierung der Rippe 5.1 Optimierungsstrategie und -prozesskette 5.2 Ziel- und Restriktionsfunktionen 5.3 Multidisziplinäre Optimierung 5.4 Diskussion der Ergebnisse 6 Zusammenfassung 7 Ausblick Anhang Abkürzungs- und Symbolverzeichnis Literatur- und Quellenverzeichnis