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Multiphysics problems are solved either with monolithic or segregated approaches. For accomplishing contrary discretisation requirements of the physics, disparate meshes are essential. This paper is comparing experimental results of different interpolation methods for a segregated coupling with monolithic approaches, implemented using a global and a local nearest neighbour method. The results show the significant influence of discretisation for multiphysics simulation.

Applying disparate meshes to the monolithic as well as the segregated calculation of finite element problems and evaluating the related numerical error is content of the contribution. This is done by an experimental evaluation of a source and a material coupling applied to a multiphysics problem. After an introduction to the topic, the evaluated multiphysics model is described based on two bidirectional coupled problems and its finite element representation. Afterwards, the considered methods for approximating the coupling are introduced. Then, the evaluated methods are described and the experimental results are discussed. A summary concludes this work.

An experimental evaluation of the numerical errors for different multiphysics coupling methods using disparate meshes is presented based on a bidirectional electro-thermal simulation. Different methods approximating the coupling values are introduced and challenges of applying these methods are given. It is also shown, that the approximation of the coupling integrals is expensive. Arguments for applying the different methods to the monolithic and the segregated solution strategies are given and applied on the example. The significant influence of the mesh density within the coupled meshes is shown. Since the projection and the interpolation methods do influence the result, a careful decision is advised.

In this contribution, existing coupling methods are described, applied and compared on their application for coupling disparate meshes within a multiphysics simulation. Knowing their performance is relevant when deciding for a monolithic or a segregated calculation approach with respect to physics dependent contrary discretisation requirements. To the authors’ knowledge, it is the first time these methods are compared with a focus on an application in multiphysics simulations and experimental results are discussed.

The purpose of this study is to use a weak light source with spatial distribution to realize light-driven fluid by adding high-absorbing nanoparticles to the droplets, thereby replacing a highly focused strong linear light source acting on pure droplets.

First, Fe₃O₄ nanoparticles with high light response characteristics were added to the droplets to prepare nanofluid droplets, and through the Gaussian light-driven flow experiment, the Marangoni effect inside a nanofluid droplet was studied, which can produce the surface tension gradient on the air/liquid interface and induce the vortex motion inside a droplet. Then, the numerical simulation method of multiphysics field coupling was used to study the effects of droplet height and Gaussian light distribution on the flow characteristics inside a droplet.

Nanoparticles can significantly enhance the light absorption, so that the Gaussian light is enough to drive the flow, and the formation of vortex can be regulated by light distribution. The multiphysics field coupling model can accurately describe this problem.

This study is helpful to understand the flow behavior and heat transfer phenomenon in optical microfluidic systems, and provides a feasible way to construct the rapid flow inside a tiny droplet by light.

The purpose of this paper is to reveal the solute segregation behavior in the molten and solidified regions during direct chill (DC) casting of a large-size magnesium alloy slab under no magnetic field (NMF), harmonic magnetic field (HMF), pulsed magnetic field (PMF) and two types of out-of-phase pulsed magnetic field (OPMF).

A 3-D multiphysical coupling mathematical model is used to evaluate the corresponding physical fields. The coupling issue is addressed using the method of separating step and result inheritance.

The results suggest that the solute deficiency tends to occur in the central part, while the solute-enriched area appears near the fillet in the molten and solidified regions. Applying magnetic field could greatly homogenize the solute field in the two-phase region. The variance of relative segregation level in the solidified cross-section under NMF is 38.1%, while it is 21.9%, 18.6%, 16.4% and 12.4% under OPMF2 (the current phase in the upper coil is ahead of the lower coil), HMF, PMF and OPMF1 (the current phase in the upper coil lags behind the lower coil), respectively, indicating that OPMF1 is more effective to reduce the macrosegregation level.

There are few reports on the solute segregation degree in rectangle slab under magnetic field, especially for magnesium alloy slab. This paper can act a reference to make clear the solute transport behavior and help reduce the macrosegregation level during DC casting.

The purpose of this paper is to present a low evaluation budget optimization strategy for expensive simulation models, such as 3D finite element models.

A 3D finite element electromagnetic model and a thermal model are developed and coupled in order to simulate the linear induction motor (LIM) to be conceived. Using the 3D finite element coupling model as a simulation model, a multi‐objective optimization with a progressive improvement of a surrogate model is proposed. The proposed surrogate model is progressively improved using an infill set selection strategy which is well‐suited for the parallel evaluation of the 3D finite element coupling model on an eight‐core machine, with a maximum of four models running in parallel.

The proposed strategy allows for a significant gain of optimization time. The 3D Pareto front composed of the finite element model evaluation results is obtained, which provides the designer with a set of optimal trade‐off solutions for him/her to make the final decision for the engineering design.

An infill set selection strategy is proposed, which allows the parallel evaluation of the finite element model, and at the same time guides the progressive construction of an improved surrogate model during the multi‐objective optimization run. The paper may stand as a good reference for researchers/engineering designers who have to deal with optimal design problems implying costly simulation models.

Copper electrodeposition acts as a crucial step in the manufacture of high-density interconnect board. The stability of plating solution and the uniformity of copper electrodeposit are the hotspot and difficulty for the research of electrodeposition. Because a large number of factors are included in electrodeposition, experimentally determining all parameters and electrodeposition conditions becomes unmanageable. Therefore, a multiphysics coupling technology was introduced to investigate microvia filling process, and the mechanism of copper electrodeposition was analyzed. The results provide a strong theoretical basis and technical guidance for the actual electroplating experiments. The purpose of this paper is to provide an excellent tool for quickly and cheaply studying the process behavior of copper electrodeposition without actually needing to execute time-consuming and costly experiments.

The interactions among additives used in acidic copper plating solution for microvia filling and the effect on the copper deposition potential were characterized through galvanostatic measurement (GM). The adsorption behavior and surface coverage of additives with various concentrations under different rotating speeds of working electrode were investigated using cyclic voltammetry (CV) measurements. Further, a microvia filling model was constructed using multiphysics coupling technology based on the finite element method.

GM tests showed that accelerator, inhibitor and leveler affected the potential of copper electrodeposition, and bis(3-sulfopropyl) disulfide (SPS), ethylene oxide-propylene oxide (EO/PO) co-polymer, and self-made leveler were the effective additives in acidic copper plating solution. CV tests showed that EO/PO–Cu⁺-Cl⁻ complex was adsorbed on the electrode surface by intermolecular forces, thus inhibiting copper electrodeposition. Numerical simulation indicated that the process of microvia filling included initial growth period, the outbreak period and the stable growth period, and modeling result was compared with the measured data, and a good agreement was observed.

The research is still in progress with the development of high-performance computers.

A multiphysics coupling platform is an excellent tool for quickly and cheaply studying the electrodeposited process behaviors under a variety of operating conditions.

The numerical simulation method has laid the foundation for mechanism of copper electrodeposition.

By using multiphysics coupling technology, the authors built a bridge between theoretical and experimental study for microvia filling. This method can help explain the mechanism of copper electrodeposition.

The purpose of this paper is to optimize experimental parameters and gain further insights into the plating process in the fabrication of high-density interconnections of printed circuit boards (PCBs) by the rotating disc electrode (RDE) model. Via metallization by copper electrodeposition for interconnection of PCBs has become increasingly important. In this metallization technique, copper is directly filled into the vias using special additives. To investigate electrochemical reaction mechanisms of electrodeposition in aqueous solutions, using experiments on an RDE is common practice.

An electrochemical model is presented to describe the kinetics of copper electrodeposition on an RDE, which builds a bridge between the theoretical and experimental study for non-uniform copper electrodeposition in PCB manufacturing. Comsol Multiphysics, a multiphysics simulation platform, is invited to modeling flow field and potential distribution based on a two-dimensional (2D) axisymmetric physical modeling. The flow pattern in the electrolyte is determined by the 2D Navier–Stokes equations. Primary, secondary and tertiary current distributions are performed by the finite element method of multiphysics coupling.

The ion concentration gradient near the cathode and the thickness of the diffusion layer under different rotating velocities are achieved by the finite element method of multiphysics coupling. The calculated concentration and boundary layer thicknesses agree well with those from the theoretical Levich equation. The effect of fluid flow on the current distribution over the electrode surface is also investigated in this model. The results reveal the impact of flow parameters on the current density distribution and thickness of plating layer, which are most concerned in the production of PCBs.

By RDE electrochemical model, we build a bridge between the theoretical and experimental study for control of uniformity of plating layer by concentration boundary layer in PCB manufacturing. By means of a multiphysics coupling platform, we can accurately analyze and forecast the characteristic of the entire electrochemical system. These results reveal theoretical connections of current density distribution and plating thickness, with controlled parameters in the plating process to further help us comprehensively understand the mechanism of copper electrodeposition.

Evaluating the multiphysics performance of an electric motor can be a computationally intensive process, especially where several complex subsystems of the motor are coupled together. For example, evaluating acoustic noise requires the coupling of the electromagnetic, structural and acoustic models of the electric motor. Where skewed poles are considered in the design, the problem becomes a purely three-dimensional (3D) multiphysics problem, which could increase the computational burden astronomically. This study, therefore, aims to introduce surrogate models in the design process to reduce the computational cost associated with solving such 3D-coupled multiphysics problems.

The procedure involves using the finite element (FE) method to generate a database of several skewed rotor pole surface-mounted permanent magnet synchronous motors and their corresponding electromagnetic, structural and acoustic performances. Then, a surrogate model is fitted to the data to generate mapping functions that could be used in place of the time-consuming FE simulations.

It was established that the surrogate models showed promising results in predicting the multiphysics performance of skewed pole surface-mounted permanent magnet motors. As such, such models could be used to handle the skewing aspects, which has always been a major design challenge due to the scarcity of simulation tools with stepwise skewing capability.

The main contribution involves the use of surrogate models to replace FE simulations during the design cycle of skewed pole surface-mounted permanent magnet motors without compromising the integrity of the electromagnetic, structural, and acoustic results of the motor.

Optimized plating conditions, included proper designs of insulating shield (IS), auxiliary cathode (AC) and different patterns, contribute to the uniformity enhancement of copper deposition.

Plating experiments were implemented in vertical continuous plating (VCP) line for manufacturing in different conditions. Multiphysics coupling simulation was brought to investigate and predict the plating uniformity improvement of copper pattern. In addition, the numerical model was based on VCP to approach the practical application.

With disproportionate current distribution, different plating pattern design formed diverse copper thickness distribution (CTD). IS and AC improved plating uniformity of copper pattern because of current redistribution. Moreover, optimized plating condition for effectively depositing more uniformed plating copper layer in varied pattern designs were derived by simulation and verified by plating experiment.

The comparison between experiment and simulation revealed that multiphysics coupling is an efficient, reliable and of course environment-friendly tool to perform research on the uniformity of pattern plating in manufacturing.

The purpose of this paper is to study the influence of the induction heating phenomenon during magnetic pulse forming (MPF) of thin walled tube components. The approach is based on the advanced use of the multiphysics finite element software FORGE® coupling electromagnetism, heat transfer and solid mechanics. Although the global contribution of thermal effects is found to be almost negligible with respect to the volume forces, it can be observed that localized softening due to the heating process induces shock absorbing behavior.

Due to the strong multiphysics couplings between solid mechanics, electromagnetism and heat transfer, it is not always obvious to quantify the contributions of the various physical phenomena. It is thus intended here to take advantage of the numerical framework and tool that has developed to dissociate and quantify the influence of Joule heating phenomena due to eddy currents during MPF processes.

In this paper, the sensitivity of the MPF process has been analyzed to the induction heating source term for a specific tube forming case. An analysis of the electric output signal shows that inductance sensitivity to heating remains small when compared to the mechanical deformation. Regarding mechanical analysis of the process, induction heating contribution has a very slight impact at the global scale, but its effect is more noticeable at the small scale where it is likely that the localized heating induces shock absorption properties through softening. The extension of these results to other materials (for which the thermal dependency of mechanical behavior is different), as well as to a larger range of energy inputs, still needs to be carried out. Such phenomena should be considered for instance for high precision forming.

The analysis of the influence of heating due to eddy currents in magnetic pulse forming processes has not been extensively studied. The originality of this work is to try to quantify its effect on the process by using a numerical-based approach.

This paper aims to deal with characterisation of the thermal performance of a hybrid tubular and cavity solar thermal receiver.

The coupled optical-flow-thermal analysis is carried out on the proposed receiver design. Modelling is performed in two and three dimensions for estimating heat loss by natural convection for an upward-facing cavity. Heat loss obtained in two dimensions by solving coupled continuity, momentum and energy equation inside the cavity domain is compared with the loss obtained using an established Nusselt number correlation for realistic receiver performance prediction.

It is found that radiation emission from a heated cavity wall to the ambient is the dominant mode of heat loss from the receiver. The findings recommend that fluid flow path must be designed adjacent to the surface exposed to irradiation of concentrated flux to limit conduction heat loss.

On-sun experimental tests need to be performed to validate the numerical study.

Numerical analysis of receivers provides guidelines for effective and efficient solar thermal receiver design.

Pressurised air receivers designed from this method can be integrated with Brayton cycles using air or supercritical carbon-dioxide to run a turbine generating electricity using a solar heat source.

The present paper proposes a novel method for coupling the flux map from ray-tracing analysis and using it as a heat flux boundary condition for performing coupled flow and heat transfer analysis. This is achieved using affine transformation implemented using extrusion coupling tool from COMSOL Multiphysics software package. Cavity surface natural convection heat transfer coefficient is obtained locally based on the surface temperature distribution.