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The purpose of this paper is to investigate the effects of H2 flow rate on improving the solder wettability of oxidized‐copper with liquid lead‐free solder (96.5Sn‐3Ag‐0.5Cu) by Ar‐H2 plasmas. The aim was to improve the solder wettability of oxidized copper from 0 per cent wetting of copper oxidized in air at 260^oC for 1 hour to 100 per cent wetting of oxidized‐copper modified by Ar‐H2 plasmas at certain H2 flow rates and to find correlations between the surface characteristics of copper and the solder wettability with liquid lead‐free solder.

To reduce the copper oxides on the surfaces of oxidized‐copper for improving solder wettability with liquid lead‐free solder, this study attempted to apply Ar‐H2 plasmas to ablate the copper oxides from the surfaces of oxidized‐copper by the physical bombardment of the Ar plasmas and to reduce the surfaces of oxidized‐copper by the chemical reaction of H2 plasmas with the surfaces of oxidized‐copper.

The solder wettability of oxidized‐copper was found to be highly dependent on the surface characteristics of the copper. The values of polar surface free energy and dispersive surface free energy on the surfaces of oxidized‐copper modified by Ar‐H2 plasmas were close to those values of solid lead‐free solder, which resulted in improved solder wettability with liquid lead‐free solder. Auger spectra indicated that the Ar‐H2 plasma modification was used to remove the copper oxides from the surfaces of oxidized‐copper.

The surface characterization of copper surfaces is typically determined by expensive surface analysis tool such as Auger Electron Spectroscopy (AES). This paper reports the results of a study of a promising technique called the sessile drop test method, for examining the surface free energies such as total surface free energy, polar surface free energy and dispersive surface free energy on the surfaces of copper to clarify how the solder wettability of oxidized‐copper with liquid lead‐free solder was enhanced by Ar‐H2 plasmas.

Two‐dimensional numerical simulations have been performed using a finite volume method that employs unstructured grids with cell‐wise local refinement and an interface‐capturing scheme to predict the shape of the free surface, thus simulating the surface wave that is created in a mold due to the flow from the submerged entry nozzle (SEN). Simulation has been done for 1:6.25 aspect ratio of the mold having a height of 2 m with parallel rectangular ports as well as 15° upward and downward ports. It has been found that for low inlet velocity of the SEN (<1 m/s) the maximum wave amplitude of the surface remains below 12 mm and no outside air is entrapped by the wave to form a bubble. However, for high inlet velocity (2 m/s or more) there is considerable fluctuations on the free surface and the maximum wave amplitude shoot up beyond 70 mm at the start up and slowly falls to about 30 mm entrapping air bubbles from the surroundings. The movement of the air bubble within the mold and its rise to the free surface where it subsequently collapses has been captured well in the numerical simulation. The overall shape of the free surface matches well, excepting the initial transience, with that of the experimentally observed free surface, although the free surface never attains a perfect steady shape neither in the experiment nor in the numerical simulation due to its continuous oscillation and breaking.

The purpose of this paper is to develop the numerical simulated methodology for sloshing motion of fluid inside a two dimension rectangular tank, and parametric studies were performed for three parameters – excitation frequency, excitation amplitude, and liquid depth.

A numerically simulated methodology by using the cell‐centered pressure‐based SIMPLE scheme and level set method for the sloshing motion of fluid in a rectangular tank has been developed. The convection term in the Navier‐Stokes equations and the equations used in the level set method were treated by the second‐order upwind scheme. The temporal derivative terms were solved by the three‐level second order scheme. The diffusion term in the Navier‐Stokes equations alone was solved by the central‐difference scheme. All algebraic equations were solved by the point Gauss‐Seidel method. A fully implicit scheme to treat the level set distancing equation, written as the advection equation, was developed. In addition, the level set distancing equation was solved by the iterative procedure to determine the variation of free surface.

For given excitation amplitude together with a liquid depth, the free surface displacement increases when the excitation frequency is less than the resonance frequency of tank. However, the free surface displacement decreases when the excitation is greater than the resonant frequency of the tank. It is noted that the maximum free surface displacement is generated under the circumstance for which the excitation frequency approaches the resonant frequency. The excitation amplitude and the excitation frequency have a substantial effect on the impact pressure on the wall of the tank being investigated.

The sloshing motion of fluid in a rectangular tank has been studied by researchers and scholars using many numerical methods; however, literature employing the level set method to study the sloshing motion of fluid is limited. In this study, the cell‐centered pressure‐based SIMPLE scheme and level set method can be employed to predict the sloshing motion. The numerical methodology can help the engineer to predict sloshing motion of fluid.

The volume of fluid (VOF) method is a numerical technique to track the developing free surfaces of liquids in motion. This method can, for example, be applied to compute the liquid flow patterns in a rotating cone reactor. For this application a spherical coordinate system is most suited. The novel derivation of the extended VOF algorithms for this class of applications is presented here. Some practical limitations of this method, that are inherent in the geometry of the described system, are discussed.

The research is directed at development of an efficient and accurate technique for modelling incompressible free surface flows in which viscous effects may not be neglected. The paper describes the methodology, and gives illustrative results for simple geometries.

The pseudospectral matrix element method of discretisation is selected as the basis for the CFD technique adopted, because of its high spectral accuracy. It is implemented as a means of solving the Navier‐Stokes equations coupled with the modified compressibility method.

The viscous solver has been validated for the benchmark cases of uniform flow past a cylinder at a Reynolds number of 40, and 2D cavity flows. Results for sloshing of a viscous fluid in a tank have been successfully compared with those from a linearised analytical solution. Application of the method is illustrated by the results for the interaction of an impulsive wave with a surface piercing circular cylinder in a cylindrical tank.

The paper demonstrates the viability of the approach adopted. The limitation of small amplitude waves should be tackled in future work.

The results will have particular significance in the context of validating computations from more complex schemes applicable to arbitrary geometries.

The new methodology and results are of interest to the community of those developing numerical models of flow past marine structures.

An investigation has been performed on the improved solder wettability of oxidized aluminum (Al) with lead-free solder (96.5Sn-3.5Ag) using Ar-H₂ plasmas. The lead-free solder wettability was raised from 62.2 per cent wetting for Al oxidized in air at 250 C for 4 h to 98.4 per cent wetting of oxidized Al modified by Ar-H₂ plasmas at a certain H₂ flow rate. This study aims to gain insight on the surface characteristics of Al affecting the solder wettability with a liquid lead-free solder.

Ar-H₂ plasmas at certain H₂ flow rates are intended to reduce Al oxides on the surfaces of oxidized Al substrates both by physical bombardments via Ar plasmas and chemical reductions with H₂ plasmas, while Al substrates are exposed in Ar-H₂ plasmas to improve the solder wettability with a liquid lead-free solder.

Surface characteristics of oxidized Al substrates have been identified to play key roles for enhanced lead-free solder wettability using Ar-H₂ plasmas. A decrease in polar surface free energy and an increase in dispersive surface free energy on the surfaces of oxidized Al substrates are exploited to advance the lead-free solder wettability. Decreased composition ratios of O to Al, detected by X-ray photoelectron spectroscopy (XPS) for oxidized Al substrates, are crucial for improved lead-free solder wettability.

XPS is typically used to analyze the surface compositions of Al oxides. To provide a rapid and non-expansive method to identify the surfaces of Al substrates prior to soldering to assure lead-free solder wettability, this study proposes a measurable skill, a so-called sessile drop test method, to investigate surface free energies such as total, polar and dispersive surface free energy on the surfaces of Al substrates, to illuminate how the lead-free solder wettability of oxidized Al is improved by Ar-H₂ plasmas.

The purpose of this paper is to establish a paint deposition pattern model applied to robotic air spray painting in order to achieve the accuracy and uniformity of paint film thickness on free‐form surface.

The paper opts for an exploratory study using the curvature circle method for air spray painting on free‐form surface to construct a spray gun model. First, a paint deposition pattern model of ellipse dual‐β distribution is fitted on the basic of experimental data from robotic air spray painting. Second, a spray gun model is proposed using the curvature circle method for air spray painting on free‐form surface. The theoretical result is coincident with the film thickness in verification experiment spraying a cylinder surface. The biggest error of the sample points between the theoretical and experimental results is less than 4 μm, thereby the correctness and effectiveness of the proposed model is validated.

The paper provides a specific theoretical and methodological support for the realization of process planning and simulation system in surface spray manufacturing. It will make the future developed system meet the actual processing requirement. At the same time, it is more representative.

The paper finds an approach to solve paint deposition pattern model suitable to free‐form surface. The present method can be applied to the complex reality of topological relation for actual workpiece surface to be painted.

The purpose of this paper is to show how a surface tension model and an eddy viscosity based on the Smagorinsky sub‐grid scale model, which belongs to the Large‐Eddy Simulation (LES) theory for turbulent flow, have been introduced into ISPH (Incompressible smoothed particle hydrodynamics) method. In addition, a small modification in the source term of pressure Poisson equation has been introduced as a stabilizer for robust simulations. This stabilization generates a smoothed pressure distribution and keeps the total volume of fluid, and it is analogous to the recent modification in MPS.

The surface tension force in free surface flow is evaluated without a direct modeling of surrounding air for decreasing computational costs. The proposed model was validated by calculating the surface tension force in the free surface interface for a cubic‐droplet under null‐gravity and the milk crown problem with different resolution models. Finally, effects of the eddy viscosity have been discussed with a fluid‐fluid interaction simulation.

From the numerical tests, the surface tension model can handle free surface tension problems including high curvature without special treatments. The eddy viscosity has clear effects in adjusting the splashes and reduces the deformation of free surface in the interaction. Finally, the proposed stabilization appeared in the source term of pressure Poisson equation has an important role in the simulation to keep the total volume of fluid.

An incompressible smoothed particle hydrodynamics is developed to simulate milk crown problem using a surface tension model and the eddy viscosity.

The purpose of this paper is to develop an efficient and accurate mesh-less method to simulate free flows with continuous deformation in boundary positions.

A two-step pressure projection method in a Lagrangian form is used to solve the governing equations of mass and momentum conservation. In the first step, velocity field is calculated in which incompressibility is not enforced. In the second step, a pressure Poisson equation is applied to satisfy incompressibility conditions. The numerical proposed method is used for spatial discretization of the governing equations. Three benchmark-free surface problems, namely, dam break, solitary wave propagation and evolution of an elliptical bubble with available experimental results and analytical solutions, are used to test the accuracy of the proposed method. The results prove the accuracy of the method in simulating free surface problems.

The Voronoi diagram instead of kernel function summation can be used to estimate the particle or nodal volume concept in particle-based (mesh-less) methods for function approximation. This idea probably works well especially for highly irregular node distributions.

The continuous moving least squares shape functions are applied for function approximation, and the Voronoi diagram concept is also used to estimate region influence of computational nodal points or particle volumes. Combinations of these two concepts and finite differences formulation for first derivatives gives an accurate numerical model for Laplacian operator in the proposed method.

Automatic trajectory generation for spray painting is highly desirable for today’s automotive manufacturing. Generating paint gun trajectories for free‐form surfaces to satisfy paint thickness requirements is still highly challenging due to the complex geometry of free‐form surfaces. In this paper, a CAD‐guided paint gun trajectory generation system for free‐form surfaces has been developed. The system utilizes the CAD information of a free‐form surface to be painted and a paint gun model to generate a paint gun trajectory to satisfy the paint thickness requirements. A paint thickness verification method is also provided to verify the generated trajectories. The simulation results have shown that the trajectory generation system achieves satisfactory performance. This trajectory generation system can also be applied to generate trajectories for many other CAD‐guided robot trajectory planning applications.