Capillary driven flow of polydimethylsiloxane in open rectangular microchannels.

The flow of liquid polydimethylsiloxane (PDMS, Dow Corning Sylgard 184, 10 : 1 base to cross-linker ratio) in open, rectangular silicon microchannels, with and without a coating (100 nm) of poly-tetra-fluoro-ethylene (PTFE), was studied. Photolithographic patterning and etching of silicon wafers was used to create microchannels with a range of widths (∼5-50 µm) and depths (5-20 µm). Experimental PDMS flow rates in both PTFE-coated and uncoated channels were compared to an analytical model based on the work of Lucas and Washburn. The experimental flow rates matched the predicted flow rates reasonably well when the channel aspect ratio (width to depth), p, was less than 2. For channels with p > 2, the observed flow rates progressively lagged model predictions with increasing p. The experimental data, including zero flow rates in certain high aspect ratio PTFE-coated channels, can largely be explained by changes in the front and upper meniscus morphology of the flow as the channel aspect ratio is varied. The results strongly suggest that meniscus morphology needs to be taken into account to accurately model capillary flow in microchannels, especially those with large aspect ratios.

Materials design for hypersonics.

Hypersonic vehicles must withstand extreme conditions during flights that exceed five times the speed of sound. These systems have the potential to facilitate rapid access to space, bolster defense capabilities, and create a new paradigm for transcontinental earth-to-earth travel. However, extreme aerothermal environments create significant challenges for vehicle materials and structures. This work addresses the critical need to develop resilient refractory alloys, composites, and ceramics. We will highlight key design principles for critical vehicle areas such as primary structures, thermal protection, and propulsion systems; the role of theory and computation; and strategies for advancing laboratory-scale materials to manufacturable flight-ready components.

High-throughput quantification of quasistatic, dynamic and spall strength of materials across 10 orders of strain rates.

The response of metals and their microstructures under extreme dynamic conditions can be markedly different from that under quasistatic conditions. Traditionally, high strain rates and shock stresses are achieved using cumbersome and expensive methods such as the Kolsky bar or large spall experiments. These methods are low throughput and do not facilitate high-fidelity microstructure-property linkages. In this work, we combine two powerful small-scale testing methods, custom nanoindentation, and laser-driven microflyer (LDMF) shock, to measure the dynamic and spall strength of metals. The nanoindentation system is configured to test samples from quasistatic to dynamic strain-rate regimes. The LDMF shock system can test samples through impact loading, triggering spall failure. The model material used for testing is magnesium alloys, which are lightweight, possess high-specific strengths, and have historically been challenging to design and strengthen due to their mechanical anisotropy. We adopt two distinct microstructures, solutionized (no precipitates) and peak-aged (with precipitates) to demonstrate interesting upticks in strain-rate sensitivity and evolution of dynamic strength. At high shock-loading rates, we unravel an interesting paradigm where the spall strength vs. strain rate of these materials converges, but the failure mechanisms are markedly different. Peak aging, considered to be a standard method to strengthen metallic alloys, causes catastrophic failure, faring much worse than solutionized alloys. Our high-throughput testing framework not only quantifies strength but also teases out unexplored failure mechanisms at extreme strain rates, providing valuable insights for the rapid design and improvement of materials for extreme environments.

Looking at education through the microscope.

Advanced research microscopes in universities can be used to enhance the education of STEM students, as demonstrated by initiatives at Johns Hopkins University that give students the opportunity to get hands-on experience with sophisticated microscopes.