Optimizing the structure of micromixers to improve the mixing efficiency is of great significance for chemical engineering and biology fields. In this study, an optimization of the microchannel in two liquids mixing is carried out based on computational fluid dynamics (CFD) and response surface methodology. Firstly, CFD simulations were performed to investigate the mixing flow field and mixing efficiency in the microchannel by considering different process and structure parameters (e.g., feed pressure p, microchannel width w). The response surface methodology was adopted to construct a fitting surface by CFD discrete working conditions. Then, an optimized microchannel width w was searched using the parallel particle swarm optimization (PPSO) algorithm from the response surface. Lastly, the searched optimum was validated by CFD simulation again, and the final result showed that the predicted mixing efficiency from the response surface model is well confirmed by CFD simulation. On average, the new optimized microchannel width of 1.634 mm performs higher flow flux and mixing efficiency than the original width of 1.5 mm, increasing 13.51% and 2.45%, respectively.

In this paper, the geometric effect on flow structure and mixing performance of two miscible fluids (deionized water and glycerol) in a planetary centrifugal mixer (PCM) during the spin-up is numerically evaluated, using the OpenFOAM interMixingFoam solver. Six different aspect ratios, specifically 0.5, 1, 1.25, 1.5, 2, and 2.5, are considered. The flow structure in each geometric configuration is illustrated by the liquid interface and vorticity isosurface represented by the Q criterion, while the mixing performance is evaluated in terms of a mixing index $MI$. As the aspect ratio increases from small to large, $MI$ first increases and then decreases. The peak $MI$ at the end of spin-up reaches 0.196 for the aspect ratio of 1.25, rather than the other five aspect ratios in our study. The mechanism analysis shows that under an aspect ratio of 1.25, the vortex structure is most violently dissipated, the interface collapse degree is the largest, and the low-velocity region volume is the smallest, which enhances the chaotic convection mixing.

To overcome the low strength of conventional polytetrafluoroethylene/aluminum (PTFE/Al) reactive materials and the insufficient reaction efficiency of aluminum, this study introduces highly reactive aluminum–cerium alloys (Al-Ce-1#, -2#, and -3#, with Ce contents of 30, 50, and 70%, respectively; the primary phase in Al-Ce-3# is Al₂Ce) with a multiscale structural design (comprising both micron-sized and nano-sized particles) into an ammonium perchlorate (AP) matrix. Al/AP reactive materials and Al-Ce/AP reactive materials with varying Ce contents were prepared. The thermal decomposition characteristics, dynamic mechanical properties, and impact ignition behavior were systematically investigated using differential scanning calorimetry (DSC) and split Hopkinson pressure bar (SHPB) experiments. The results demonstrate that the addition of Al₂Ce significantly alters the thermal decomposition process of AP, substantially lowering its decomposition temperature (by approximately 69 °C) and promoting concentrated exothermic decomposition. SHPB tests reveal that Al₂Ce/AP composites exhibit higher dynamic yield strength and flow stress than the Al/AP, accumulating faster strain energy density under impact loading, which indicates a more violent fragmentation failure mode. This enhanced mechanical failure behavior, which provides highly reactive interfaces and promotes hotspot formation, synergizes with the catalytic effect of Al₂Ce on AP decomposition. Together, these mechanisms jointly improve the impact ignition sensitivity of the material, significantly lowering its ignition threshold and shortening its combustion duration. This study confirms that Al₂Ce/AP is a novel reactive material combining excellent dynamic mechanical properties with outstanding impact reactivity, providing theoretical and technical support for the application of highly reactive rare-earth aluminum alloys in aluminum-based reactive materials.