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W W W. C O M S O L . C O M
2014
T H E M U LT I P H Y S I C S S I M U L AT I O N M A G A Z I N E
Image supplied by Boeing. Copyright © Boeing
COMSOL
NEWS
BOEING MODELS
COMPOSITES
WITH LIGHTNING
PROTECTION
P. 4
BOSTON SCIENTIFIC
ENGINEERS REVOLUTIONIZE
MEDICAL DEVICE DESIGN
P. 10
NASA OPTIMIZES MANNED
SPACECRAFT DEVICES USING
MULTIPHYSICS SIMULATION
P. 16
Verify, Optimize, Revolutionize:
Multiphysics Simulation Delivers
Innovative Design Solutions
This year’s issue of COMSOL News provides
you with a front row seat to show how
multiphysics simulation is advancing
product development. Engineers and
researchers strive to stay ahead of the game
by employing innovative design solutions
that result in reduced cost and increased
revenues while providing safer and better
products. But how do they do it?
You may have identified the familiar
Boeing 787 Dreamliner featured on the
cover. For this innovative jet airliner
comprised of more than 50 percent carbon
fiber reinforced plastic, engineers at
Boeing used multiphysics simulation to
investigate and verify thermal expansion in
composite materials with expanded metal
foil for lightning strike protection. Boston
Scientific engineers are revolutionizing
medical device design by gaining the
knowledge required to control the
underlying release mechanism of drug-
eluting stents. Simulation provided vital
optimization and design guidance to NASA
engineers involved in the development of
life support systems providing breathable
air and drinkable water for astronauts.
These are just a few highlights of the
many successes achieved by the engineers
and researchers relying on the power and
accuracy of multiphysics simulation. From
lab-on-a-chip to building physics, to MEMS
& robotics and containerless processing,
there are plenty of exciting projects you
can read about.
It’s been an honor to work with the
talented engineers, researchers, and
designers featured in the articles and it is my
pleasure to bring you this edition of COMSOL
News, the multiphysics simulation magazine.
Enjoy your reading,
4
CONTENTS
AEROSPACE
Boeing Simulates Thermal
Expansion in Composites with
Expanded Metal Foil for Lightning
Protection of Aircraft Structures
AUTOMOTIVE
28
Optimizing Built-in Tire Pressure
Monitoring Sensors
NUCLEAR ENGINEERING
30
Researching a New Fuel for the
HFIR: Advancements at ORNL
Require Multiphysics Simulation
to Support Safety and Reliability
STEELMAKING
8
Continuous Casting: Optimizing
Both Machine and Process with
Simulation
MEDICAL TECHNOLOGY
10
Simulating the Release
Mechanism in Drug-Eluting Stents
ACOUSTIC STREAMING
34
Gaining Insight into Piezoelectric
Materials for Acoustic Streaming
IMAGING SPECTROMETRY
13
Keeping Cool: SRON Develops
Thermal Calibration System for
Deep-Space Telescope
MATERIALS SCIENCE
36
Simulation-Led Strategy for
Corrosion Prevention
BIOENGINEERING
40
Patterning Cells with the Flip
of a Switch for Bioengineering
Applications
SPACECRAFT ATMOSPHERE
REVITALIZATION
16
Simulation Helps Improve
Atmosphere Revitalization
Systems for Manned Spacecraft
COMPUTATIONAL
ELECTROMAGNETICS
42
Scattering of Electromagnetic
Waves by Particles
PASSIVE VACCINE STORAGE
18
Innovative Thermal Insulation
Techniques Bring Vaccines to the
Developing World
CONTAINERLESS PROCESSING
44
Floating on Sound Waves with
Acoustic Levitation
NUCLEAR WASTE STORAGE
20
Battling Corrosion in Nuclear Waste
Storage Facilities
MEMS & ROBOTICS
46
Actuation Technique for
Miniature Robots Developed
using Multiphysics Simulation
BUILDING PHYSICS
22
Using Multiphysics Simulation to
Prevent Building Damage
BIOTECHNOLOGY
24
Optimizing Hematology Analysis:
When Physical Prototypes Fail,
Simulation Provides the Answers
GUEST EDITORIAL
48
From Concept to Market:
Simulation Narrows the Odds
in Product Innovation
Valerio Marra
TECHNICAL MARKETING MANAGER
COMSOL, Inc.
INTERACT WITH THE COMSOL COMMUNITY
You can comment on this year’s stories via
BLOG
comsol.com/blogs
FORUM
comsol.com/community/forums
FACEBOOK
facebook.com/multiphysics
TWITTER
twitter.com/COMSOL_Inc
We welcome your comments on COMSOL
NEWS; contact us at
info@comsol.com.
© 2014,COMSOL. COMSOL News is published by
COMSOL, Inc. and its associated companies. COMSOL,
COMSOL Multiphysics, Capture the Concept, COMSOL
Desktop, and LiveLink are either registered trademarks
or trademarks of COMSOL AB. All other trademarks are
the property of their respective owners, and COMSOL
AB and its subsidiaries and products are not affiliated
with, endorsed by, sponsored by, or supported by those
trademark owners. For a list of such trademark owners,
see www.comsol.com/trademarks
ON THE COVER
”787-8 Flying Over Oregon Coast” from
www.boeingimages.com.
2 | COMSOL NEWS | 2014
She Created the Future.
Monika Weber, Founder and CEO of
Integrated Microfluidic Devices, was
the Grand Prize Winner of the 2011
Create the Future Design Contest.
Fluid-Screen (formerly Alpha-Screen) brings the functionality of a lab to a small portable device that fits in the
palm of your hand and detects bacteria from blood and water in less than 30 minutes. Fluid-Screen uses a
patented electric field and biosensor technology to rapidly collect and detect bacteria.
“After being honored with the 2011 Create the Future Design Contest Grand Prize, the funding and publicity
from the award was instrumental in helping us speed up the development of Fluid-Screen and make a
working beta prototype,” says Monika Weber, Founder and CEO of Integrated Microfluidic Devices.
Fluid-Screen product test series will be
launched in 2015 and enter the market in 2016.
Now it’s Your Turn.
To enter, get details at
THE
www.createthefuturecontest.com
S P O N S O R E D
B Y
DESIGN CONTEST 2014
C A T E G O R Y
S P O N S O R
P R I Z E
S P O N S O R
COMPOSITES
|
AEROSPACE
Boeing, WA, USA
Boeing Simulates Thermal Expansion
in Composites with Expanded
Metal Foil for Lightning Protection
of Aircraft Structures
Modern aircraft such as the Boeing 787 Dreamliner are comprised of more than fifty percent
carbon fiber composite requiring the addition of expanded metal foil for lightning strike
protection. Researchers at Boeing are using simulation to verify that protective coatings on
the metal foil will not fail due to thermal stress arising from a typical flight cycle.
BY JENNIFER A. SEGUI
The Boeing 787 Dreamliner is
innovative in that it is comprised of
more than fifty percent carbon fiber
reinforced plastic (CFRP) due to the
material’s light weight and exceptional
strength. Figure 1 shows the extensive
use of composite materials throughout
the aircraft. Although CFRP composites
inherently have many advantages,
they cannot mitigate the potentially
damaging electromagnetic effects
from a lightning strike. To solve this
problem, electrically conductive
expanded metal foil (EMF) can be
added to the composite structure layup
to rapidly dissipate excessive current
and heat for lightning protection of
CFRP in aircraft.
Engineers at Boeing Research
and Technology (BR&T) are using
multiphysics simulation and physical
measurements to investigate the
effect of the EMF design parameters
on thermal stress and displacement
FIGURE 1.
Advanced composites used throughout the Boeing 787 account for more than fifty percent of the aircraft body
1
.
4 | COMSOL NEWS | 2014
COMPOSITES
|
AEROSPACE
FIGURE 2.
At left is the composite structure layup from the COMSOL model and, at right,
the geometry of the expanded metal foil. SWD and LWD correspond to short way of the
diamond and long way of the diamond. The mesh aspect ratio: SWD/LWD is one of the
parameters varied in the simulations.
in each layer of the composite
structure layup shown at left in Figure
2. Stress accumulates in the protective
coating of the composite structure as
a result of thermal cycling due to the
typical ground-to-air flight cycle. Over
time, the protective coating may crack
providing an entrance for moisture
and environmental species that can
cause corrosion of the EMF, thereby
reducing its electrical conductivity
and ability to perform its protective
function.
Contributing to the research effort
at BR&T are project lead Jeffrey Morgan
from Sealants and Electromagnetic
Materials, Associate Technical Fellow
Robert Greegor from Applied
Physics leading the simulation, Dr.
Patrice Ackerman from Sealants and
Electromagnetic Materials leading the
testing, and Technical Fellow Quynhgiao
Le. Through their research, they aim
to improve overall thermal stability in
the composite structure and therefore
reduce the risks and maintenance
costs associated with damage to the
protective coating.
colleagues using COMSOL Multiphysics
®
in order to evaluate the thermal
stress and displacement in each layer
of a one-inch square sample of the
composite structure layup.
The structure of the EMF layer
is shown at right in Figure 2. In this
study, the EMF height, width of the
mesh wire, aspect ratio, metallic
composition, and surface layup
structure were varied to evaluate
their impact on thermal performance
throughout the entire structure. The
metallic composition of the EMF was
either aluminum or copper where an
aluminum EMF requires additional
fiberglass between the EMF and
the composite to prevent galvanic
corrosion.
The material properties for each
layer including the coefficient of
thermal expansion, heat capacity,
density, thermal conductivity, Young’s
modulus, and Poisson’s ratio were
added to the COMSOL model as
custom-defined values and are
summarized in Figure 3. The coefficient
of thermal expansion of the paint
layer is defined by a step function
that represents the abrupt change
in thermal expansion at the glass
transition temperature of the material.
In the CTE model, the Thermal
Stress multiphysics interface couples
solid mechanics with heat transfer
to simulate thermal expansion and
solve for the displacement throughout
the structure. The simulations were
confined to heating of the composite
structure layup as experienced
upon descent in an aircraft where
final and initial temperatures were
defined in the model to represent the
ground and altitude temperatures,
respectively.
IMPACT OF EMF ON STRESS
AND DISPLACEMENT
The results of the COMSOL simulations
were analyzed to quantitatively
determine the stress and displacement
in each layer upon heating and for
SIMULATING THERMAL EXPANSION
IN AIRCRAFT COMPOSITES
In the surface protection scheme shown
at left in Figure 2, each layer including
the paint, primer, corrosion isolation
layer, surfacer, EMF, and the underlying
composite structure contribute to the
buildup of mechanical stress in the
protective coatings over time as they
are subject to thermal cycling. The
geometry in the figure is from the
coefficient of thermal expansion (CTE)
model developed by Greegor
2,3
and his
FIGURE 3.
Ratio of each material parameter relative to the paint layer. The paint layer
shows higher values of CTE, heat capacity, and Poisson’s ratio indicating that it will
undergo compressive stress and tensile strain upon heating and cooling.
COMSOL NEWS | 2014 | 5

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