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A thorough understanding of media tightness in automotive electronics is crucial for ensuring more reliable and compact product designs, ultimately improving product quality. Concerning the fundamental characteristics of fluid leakage issues, the dynamic wetting and penetration behavior on small scales is of special interest and importance. In this work, four T-shaped microchannels with one inlet and two outlets are experimentally investigated in terms of contact angle dynamics and interface movement over time, generating novel insight into the wetting mechanisms and fluid distribution. With a main channel width of 1 mm, a crevice width of w = 0.3 mm, 0.4 mm and a rounding edge radius of r = 0.1 mm, 0.2 mm, the geometrical effects on the fluid penetration depth in the crevice and the interface edge pinning effect are analyzed quantitatively using an automated image processing procedure. It is found that the measured dynamic contact angles in all parts can be well described by molecular kinetic theory using local contact line velocities, even with local surface effects and abrupt geometry changes. Moreover, a smaller crevice width, a sharper edge and a larger flow velocity tend to enhance the interface pinning effect and prevent fluid penetration into the crevice. The rounding radius has a more significant effect on the interface pinning compared with crevice width. The experimental data and image processing algorithm are made publicly available.

The efficient and voidless filling of microcavities is of great importance for Lab-on-a-Chip applications. However, predicting whether microcavities will be filled or not under different circumstances is still difficult due to the local flow effects dominated by surface tension. In this work, a close-up study of the microcavity filling process is presented, shedding light on the mechanisms of the filling process using experimental insights accompanied by 3D numerical simulations. The movement of a fluid interface over a microcavity array is investigated optically under consideration of different fluids, capillary numbers, and cavity depths, revealing a regime map of different filling states. Moreover, the transient interface progression over the cavities is analyzed with attention to small-scale effects such as pinning. Besides the visual analysis of the image series, quantitative data of the dynamic contact angle and the interface progression is derived using an automated evaluation workflow. In addition to the experiments, 3D Volume-of-Fluid simulations are employed to further investigate the interface shape. It is shown that the simulations can not only predict the filling states in most cases, but also the transient movement and shape of the interface. The data and code associated with this work are publicly available at Bosch Research GitHub and at the TUDatalib data repository., Comment: submitted to International Journal of Multiphase Flow

We provide an implementation of the unstructured Finite-Volume Arbitrary Lagrangian / Eulerian (ALE) Interface-Tracking method for simulating incompressible, immiscible two-phase flows as an OpenFOAM module. In addition to interface-tracking capabilities that include tracking of two fluid phases, an implementation of a Subgrid-Scale (SGS) modeling framework for increased accuracy when simulating sharp boundary layers is enclosed. The SGS modeling framework simplifies embedding subgrid-scale profiles into the unstructured Finite Volume discretization. Our design of the SGS model library significantly simplifies adding new SGS models and applying SGS modeling to Partial Differential Equations (PDEs) in OpenFOAM.

Preventing fluid penetration poses a challenging reliability concern in the context of power electronics, which is usually caused by unforeseen microfractures along the sealing joints. A better and more reliable product design heavily depends on the understanding of the dynamic wetting processes happening inside these complex microfractures, i.e. microchannels. A novel automated image processing procedure is proposed in this work for analyzing the moving interface and the dynamic contact angle in microchannels. In particular, the developed method is advantageous for experiments involving non-transparent samples, where extracting the fluid interface geometry poses a significant challenge. The developed method is validated with theoretical values and manual measurements and exhibits high accuracy. The implementation is made publicly available. The developed method is validated and applied to experimental investigations of forced wetting with two working fluids (water and 50 wt% glycerin/water mixture) in four distinct microchannels characterized by different dimensions and curvature. The comparison between the experimental results and molecular kinetic theory (MKT) reveals that the dynamic wetting behavior can be described well by MKT, even in highly curved microchannels. The dynamic wetting behavior shows a strong dependency on the channel geometry and curvature.

Combining machine learning (ML) with computational fluid dynamics (CFD) opens many possibilities for improving simulations of technical and natural systems. However, CFD+ML algorithms require exchange of data, synchronization, and calculation on heterogeneous hardware, making their implementation for large-scale problems exceptionally challenging. We provide an effective and scalable solution to developing CFD+ML algorithms using open source software OpenFOAM and SmartSim. SmartSim provides an Orchestrator that significantly simplifies the programming of CFD+ML algorithms and a Redis database that ensures highly scalable data exchange between ML and CFD clients. We show how to leverage SmartSim to effectively couple different segments of OpenFOAM with ML, including pre/post-processing applications, solvers, function objects, and mesh motion solvers. We additionally provide an OpenFOAM sub-module with examples that can be used as starting points for real-world applications in CFD+ML.

Non-orthogonality errors in unstructured Finite Volume methods for simulating incompressible two-phase flows may break the force-balanced discretization. We show that applying the same explicit non-orthogonality correction for all gradient terms in the context of segregated solution algorithms is not sufficient to achieve force balance. To ensure force balance, we introduce a straightforward and deterministic residual-based control of the non-orthogonality correction, which removes the number of non-orthogonality corrections as a free parameter from the simulation. Our method is directly applicable to different unstructured finite-volume two-phase flow simulation methods as long as they discretize the one-field formulation of incompressible two-phase Navier-Stokes equations. We demonstrate force balance for the surface tension force and the gravity force near linear solver tolerance for an algebraic and a geometric Volume-of-Fluid method using the stationary droplet and stationary water column verification cases on polyhedral unstructured meshes with varying levels of non-orthogonality.