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Journal of Micromechanics and Microengineering

J. Micromech. Microeng. 29 (2019) 075006 (9pp) https://doi.org/10.1088/1361-6439/ab1db7

Enhancement of power output in passive


micro-direct methanol fuel cells with
optimized methanol concentration
and trapezoidal flow channels
Arjun Sunil Rao1,3 , K R Rashmi2 , D V Manjunatha1, A Jayarama2,3
and Richard Pinto1
1
  Department of Electronics and Communication Engineering, Alva’s Institute of Engineering
and Technology, Moodbidri, D. K., Karnataka, India
2
  Department of Physics, Alva’s Institute of Engineering and Technology, Moodbidri, D. K., Karnataka,
India

E-mail: arjunsr92@gmail.com and jrmarasalike@gmail.com

Received 12 March 2019, revised 10 April 2019


Accepted for publication 29 April 2019
Published 28 May 2019

Abstract
This work presents design, fabrication and optimization of methanol concentration and flow
channel cross-sectional geometry for enhanced power output in passive micro-direct methanol
fuel cells. Passive micro-direct methanol fuel cells are fabricated with flow channels in
silicon having both rectangular and trapezoidal cross-sectional geometry for flow of methanol
at anode and air at cathode using microelectromechanical systems (MEMS) fabrication
technique. The experiments are conducted at 25 °C by feeding methanol with a flow rate of
25 μl min−1 and supply of air at cathode by air-breathing method. Results show a peak
in open circuit voltage and power density at 7 M methanol concentration for passive
micro-direct methanol fuel cells having both rectangular and trapezoidal cross-sectional
geometry. A study of influence of silicon flow channel cross-sectional geometry on passive
micro-direct methanol fuel cell performance shows for the first time that the flow channels
with trapezoidal cross-section enhance the power density (6.64 mW cm−2) nearly by a factor
of two compared to that of flow channels with rectangular cross-section (3.9 mW cm−2) at
7 M methanol concentration.We believe that, though our results of significant enhancement
of power density with trapezoidal fuel flow channels are obtained with micro-direct methanol
fuel cells as a platform, they should also be applicable to other proton exchange membrane
fuel cells with ethanol or humidified hydrogen as fuel.

Keywords: passive micro-direct methanol fuel cell, gas diffusion layer, trapezoidal flow
channels, methanol concentration

(Some figures may appear in colour only in the online journal)

1. Introduction is considerable body of work carried out to enhance the power


density and fuel conversion efficiency over the last decade in
Passive micro-direct methanol fuel cells (μ-DMFCs) have the field of μ-DMFCs [4–8]. While the efficiency and power
evolved over the last few years because of numerous advantages, density depend on thickness and equivalent weight of proton
such as high power density, reliability and high fuel conversion exchange membrane (PEM), both power density and fuel con-
efficiency which could lead to many applications [1–3]. There version also depend upon methanol concentration, flow channel
3
Authors to whom any correspondence should be addressed. geometry and operating temperature [9–11].

1361-6439/19/075006+9$33.00 1 © 2019 IOP Publishing Ltd  Printed in the UK


J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al

One of the most important parameters which limits the per- due to excessive pressure drop [10, 31]. Hence, the optimum
formance of μ-DMFCs is fuel crossover from the anode side fuel flow channel width, land-width and flow channel depth
to the cathode side through PEM (such as nafion) [12] and also (in trapezoidal cross-section) is essential for best performance
the formation of CO2 bubbles at the anode [13]. Crossover is a of fuel cells [10]. Since, there are only simulation studies
phenomenon of methanol diffusion through PEM and it is found on the effect of cross-sectional geometry of flow channels
to be dependent on methanol concentration and PEM thick- on the performance of μ-DMFC, it is essential to study its
ness [14]. Methanol crossover decreases the cathode potential effect experimentally for best performance of μ-DMFCs with
at open circuit which causes a mixed potential on the cathode optim­ized methanol concentration.
thereby diminishing the overall cell performance [5, 15]. This paper reports optimization of methanol concentration
In other words, the fraction of methanol which diffuses and study of effect of cross-sectional geometry of fuel flow
through nafion membrane reacts with oxygen at the cathode, channels in passive μ-DMFCs. Experiments were carried out
thereby causing an internal short circuit and the consequent by fabricating passive μ-DMFCs with rectangular and trap-
loss of current in the external circuit [16, 17]. The crossover ezoidal cross-sectional flow channels etched in silicon wafers
increases with the methanol concentration and hence, can be using microelectromechanical systems (MEMS) fabrication
limited by utilizing a lower methanol concentration. In other process. The results of a very significant enhancement in power
words, while a lower methanol concentration cannot provide density, nearly by a factor of two, realized in μ-DMFCs with
enough reactant to the catalyst sites due to the mass transfer trapezoidal methanol flow channels as compared to μ-DMFCs
limitation, a higher concentration tends to harm the μ-DMFC with rectangular fuel flow channels are reported in this paper.
performance as a result of enhanced methanol crossover.
Hence, a trade-off has to be found for methanol concentration.
2. Experimental
It has to be sufficiently small to diminish crossover through
the membrane, but at the same time, high enough to cause a 2.1. Design and fabrication of passive μ-DMFCs
high performance in μ-DMFCs [16]. This optimum methanol
concentration depends on μ-DMFC design, the most impor- Passive μ-DMFCs were designed and fabricated using sil-
tant parameter in the design being the membrane thickness. icon flow channels for flow of methanol at anode and air at
In an active μ-DMFC, a fuel pump and an air/oxygen blower cathode. The heart of the μ-DMFC is membrane electrode
are used which result in a maximum power density that can be assembly (MEA) which has an active area of 2.89 cm2 in our
realized at low methanol concentrations [18, 19]. On the other design. MEA consists of micro-porous gas diffusion layer
hand, a passive μ-DMFC has a built-in fuel reservoir for supply (GDL) i.e. Toray carbon paper, which regulates the flow of
of methanol of required concentration, thereby eliminating the methanol to the catalyst at the anode, a high efficiency catalyst
need for pumps [20]. Further, due to the low fuel flow rate in layer (Pt–Ru) [20, 32] for the generation of protons (H+) from
passive μ-DMFCs, they require higher methanol concentrations methanol, a high proton conductance membrane layer (Nafion
to realize maximum power density with minimal methanol 117) for the transfer of protons and a high efficiency cata-
crossover [9, 21]. Hence, the optimum methanol concentration lyst (Pt) at the cathode [20, 33] for the conversion of oxygen
for a passive μ-DMFC with low fuel flow rate may not be the (from air), protons and electrons (from external circuit) into
same as that of active μ-DMFC with high fuel flow rate [15]. water. A metallic layer (Cr–Au) on the flow channels of sil-
Reports indicate that one of the important design considera- icon chips (both at anode and cathode) is used for the exit of
tions determining methanol flow velocity is the cross-sectional electrons from anode through the external circuit and entry
geometry of flow channels at anode/cathode in μ-DMFCs [10, into the cathode for charge balance. A schematic of passive
22–26]. In μ-DMFC design, there is an optimal micro-channel μ-DMFC with two identical aluminium reservoirs is shown
geometry for fuel delivery; and it is reported that the min- in figure 1 and its exploded view showing detailed description
imal flow channel cross-section is about 100 μm  ×100 μm for silicon-based cell assembly is shown in figure 2.
[27]. Further, flow channel depth should also be an optimum
size [28], because too shallow channel depth will hamper the 2.1.1.  Fabrication of flow channels in silicon wafers.  MEMS
removal of CO2 at the anode side in the case of methanol/ technology was used for the fabrication of micro-flow chan-
ethanol fuel cells [13, 20, 25]. There are very few studies on nels for flow of methanol at anode and air at cathode. The
the influence of triangular/trapezoidal and rectangular cross- flow channels in silicon wafers were fabricated with cross-
sectional geometry of fuel flow channels on optimal fuel cell strip design since this design gives better fuel cell perfor-
performance [10, 29]; the simulation studies on trapezoidal mance [34]. In this process, 2 inch silicon wafers of 〈1 1 0〉
cross-section have shown that it is more effective in ensuring and 〈1 0 0〉 orientations were used which give rectangular and
uniform reactant distribution over the reactant area of the fuel trapezoidal cross-sectional geometries, respectively when
cell [30]. Pressure drop in the fuel flow channel should not be etched. The process flow schematic for fabrication of micro-
too high which limits the flow of reactants; on the other hand, flow channels in silicon is shown in figure  3. The process
it should not be too low thereby meaning reactants spend very involves following steps: (a) wet oxidation of silicon wafers
little time at the reaction sites. Simulations show that as the for growth of 1000 nm thick SiO2; (b) spin coating of positive
land-width decreases (from the rectangular cross-section), photo resist (PPR) on both sides of silicon wafers followed
fuel (methanol/hydrogen) consumption increases till an by ultraviolet (UV) lithography using level 1 through-hole
optimal land-width below which fuel consumption decreases mask to define through holes; (c) development of PPR using

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J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al

Figure 1.  Schematic of passive μ-DMFC with aluminium


reservoirs.

Figure 2.  Exploded view of passive μ-DMFC showing detailed


description for silicon-based cell assembly with (a) aluminium
reserviors, (b) silicon flow channels with Cr–Au current collector,
(c) catalyst loaded GDLs, and (d) nafion 117 membrane. Figure 3.  Process flow for fabrication of micro-flow channels in
silicon wafer: (a) silicon wafer with 1000 nm SiO2; (b) spin coating
of PPR on both sides of silicon wafers followed by UV lithography
MF319 developer followed by etching of SiO2 using buffered and development; (c) etching of exposed SiO2 using BHF; (d)
hydrofluoric acid (BHF); (d) etching of silicon up to 190 μm TMAH etching of silicon using SiO2 mask for through holes;
depth using tetramethylammonium hydroxide (TMAH) as an (e) spin coating of PPR on both sides of silicon wafers followed
anisotropic etchant with SiO2 mask; (e) spin coating of PPR by second level UV lithography and development; (f) etching of
on both sides of silicon wafers followed by second level UV exposed SiO2 using BHF; (g) TMAH etching of silicon using SiO2
mask for micro-flow channels; and (h) Cr–Au sputter deposition on
lithography using level 2 flow-channel mask to define cross- silicon cross-strip micro-flow channels.
strip flow channels; (f) development of PPR by using MF319
developer followed BHF etching of exposed SiO2; (g) anis- 2.1.2. Preparation of MEA.  As mentioned earlier, the MEA
trophic TMAH etching of silicon wafers with SiO2 as mask to consists of a nafion 117 membrane sandwiched in between the
obtain flow channels of depth 100 μm (width of flow channels two catalyst loaded GDLs. Before assembling the μ-DMFC,
250 μm). While etching the flow channels, the through holes nafion membranes were cleaned with acetone and isopropyl
were likewise etched totally. (h) Bi-metallic layer of chrome alcohol (IPA). It was post baked at 100 °C for 1 h to remove
(10 nm) and gold (150 nm) [34] was then sputter-deposited on any water molecules present. 5 mg each of Pt and Ru nano-
silicon flow channels for conduction of electrons (that accu- particles were suspended in 0.2 ml of IPA. This suspension
mulate on GDL surface facing the flow channels) towards was used as catalyst at the anode of the μ-DMFCs. 10 mg Pt
external circuit. UV lithography mask design and optical nano-particles were suspended in 0.2 ml of IPA which was
microscopic image of fabricated cross-strip micro-flow chan- used as catalyst at the cathode of passive μ-DMFCs. The
nels are shown in figures 4(a) and (b), respectively. nano-particles were coated on the GDLs with 3.5 mg cm−2 of
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J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al

Figure 4.  (a) UV lithography mask design of cross-strip micro-flow


channel design, and (b) optical microscopic image of micro-flow
channels fabricated in silicon wafers using MEMS fabrication
process.

catalyst density. Figure 5 shows field emission scanning elec-


tron microscope (FESEM) image of toray carbon paper GDLs
with and without catalyst loading.

2.1.3. Assembly of μ-DMFCs.  Aluminium reservoirs were Figure 5.  FESEM images of GDLs (a) without catalyst loading,
used for storage and supply of methanol at anode [35] and air and (b) with catalyst loading.
at the cathode as shown in figures 1 and 2. Methanol solution
was fed into the anode with a flow rate of 25 μl min−1 at 25 °C. solutions of 2 M, 4 M, 6 M, 7 M and 8 M concentrations
Air-breathing mode was utilized for supply of air at cathode were used as fuel at anode of μ-DMFC operated at 25 °C
because it enhances the design flexibility which is desirable with 25 μl min−1 methanol flow rate and air-breathing at
in portable applications. Finally, the passive μ-DMFCs were cathode.
prepared by assembling the components in the following
order: starting from anode to cathode—Cr–Au sputtered sili-
con flow channels | Pt–Ru catalyst loaded GDL | nafion 117 3.  Results and discussion
membrane | Pt catalyst loaded GDL | Cr–Au sputtered silicon
flow channels. This assembly was sandwiched between two 3.1.  Effect of methanol concentration on OCV
identical aluminium reservoirs. The following two experi-
The first parameter that was studied was the effect of concen-
ments were conducted to optimize the performance of pas-
tration of methanol on OCV of passive μ-DMFCs fabricated
sive μ-DMFCs.
with rectangular and trapezoidal flow channels etched in
(a) Effect of methanol concentration on OCV of passive μ- 〈1 1 0〉 and 〈1 0 0〉 silicon wafer orientations, respectively.
DMFCs: In this case we varied methanol concentration Passive μ-DMFCs were kept vertical with methanol flowing
from 1 M to 8 M to study its effect on OCV of passive μ- through the flow channels through gravity. The concentra-
DMFCs using rectangular and trapezoidal cross-sectional tion of methanol liquid feed was varied from 1 M to 8 M and
flow channels at 25 °C with methanol flow rate of 25 μl OCVs of passive μ-DMFCs were measured at each concentra-
min−1 at anode and air-breathing at cathode. tion at 25 °C with 25 μl min−1 methanol flow rate at anode and
(b) 
Effect of cross-sectional geometry of micro-flow air-breathing at cathode. The experimental results of variation
channels on passive μ-DMFC power density: In this of OCV with methanol concentration are plotted in figure 6.
experiment, the effect of flow channels with two different It is observed that at lower concentrations, the experimental
cross-sectional geometries (rectangular and trapezoidal) results show lower OCVs due to lack of methanol at the anode
on passive μ-DMFC performance was studied. Methanol catalyst sites.

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Figure 6.  OCVs of passive μ-DMFCs with rectangular and


trapezoidal flow channels as a function of methanol concentration
obtained at 25 °C with methanol flow rate 25 μl min−1 at anode and
air-breathing at cathode.

From figure  6 it is clear that the experimentally meas-


ured OCV increases with increase in methanol concentration
showing a peak at 7 M methanol concentration. The increase
of OCV with the increase in methanol concentrations is due
to the fact that higher methanol concentrations produce more
protons as well as electrons, and also generate higher diffu-
sion force which improves the transfer rate of methanol from
reservoir to the anode side and catalyst layers through GDL.
But beyond 7 M, the OCV gradually decreases due to meth- Figure 7.  Schematic of cross-sectional geometry of flow channels:
anol crossover through nafion 117 membrane which increases (a) rectangular on 〈1 1 0〉 silicon wafer, and (b) trapezoidal on
beyond 7 M methanol concentration. In other words, when a 〈1 0 0〉 silicon wafer; micro-flow channel width, w  =  250 μm,
higher methanol concentration (beyond 7 M in our case) is depth, d  =  100 μm, and land-width, wl  =  100 μm.
used, a larger amount of methanol is oxidized at the cathode silicon wafer. This is an inherent property of anisotropic wet
(due to methanol crossover), leading to a higher mixed poten- etching of silicon with 〈1 1 0〉 and 〈1 0 0〉 orientations. The
tial. This pulls down the OCV severely. It is commonly known flow channel length and the top width (exposed to catalyst
that in the case of a passive μ-DMFC, the methanol delivery loaded GDL) in both cases are the same which are defined by
is mostly driven by a methanol concentration gradient [14]. In the design of the UV lithographic mask as seen in figure 4(a).
this situation, a lower methanol concentration cannot provide The cross-sectional FESEM images of flow channels fabri-
enough reactant to the catalyst sites due to the mass transfer cated on 〈1 1 0〉 and 〈1 0 0〉 silicon wafer orientations are
limitation, while a higher concentration also tends to harm shown in figures 8 and 9, respectively.
the μ-DMFC performance as a result of enhanced methanol A set of experiments were performed in order to study the
crossover [36]. Thus, an optimal methanol concentration of effect of cross-sectional geometry of flow channels fabricated
7 M helps to achieve an optimal passive μ-DMFC perfor- from (1) 〈1 1 0〉 silicon wafer orientation (rectangular cross-
mance by more efficient utilization of methanol. sectional geometry), and (2) 〈1 0 0〉 silicon wafer orientation
(trapezoidal cross-sectional geometry) on the performance of
passive μ-DMFCs. Polarization (I–V and I-P) curves were
3.2.  Effect of cross-sectional geometry of flow channels
obtained for μ-DMFCs at 25 °C for 2 M, 4 M, 6 M, 7 M and
etched in 〈1 1 0〉 and 〈1 0 0〉 silicon wafer orientations on
passive μ-DMFC performance 8 M methanol concentrations with flow rate of 25 μl min−1.
Shown in figures 10(a) and (b) are polarization plots of passive
We have observed that the cross-sectional geometry of the μ-DMFCs with flow channels having rectangular and trap-
flow channels which influence the flow of reactants has a ezoidal cross-sectional geometries, respectively. These results
significant bearing on the performance of passive μ-DMFCs. indicate that the performance of the passive μ-DMFC with
A schematic of cross-sectional geometry of flow channels is both types of flow channels is almost similar in the low cur­
shown in figure 7. As seen in the figure, a rectangular cross- rent density region. At higher current density regions however,
sectional geometry is obtained in 〈1 1 0〉 silicon wafer and a the passive μ-DMFC with flow channels having trapezoidal
trapezoidal cross-sectional geometry is obtained in 〈1 0 0〉 cross-section show better cell voltage and a nearly two-fold

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Figure 8.  FESEM image of micro-flow channels fabricated from Figure 9.  FESEM image of micro-flow channels fabricated from
〈1 1 0〉 silicon wafer orientation: (a) cross-section, and (b) tilted 〈1 0 0〉 silicon wafer orientation: (a) cross-section, and (b) tilted
view. view.

enhancement of power density as compared to those obtained


with rectangular cross-sectional flow channels. These results Q
Or v = ,
(2)
are true for all the methanol concentrations 2 M, 4 M, 6 M, 7 A
M and 8 M studied. As seen in figure 10, the maximum power where Q is the reactant flow rate, v is the reactant velocity and
density is obtained at 7 M methanol concentration which is A is the cross-sectional area of the flow channel.
found to be optimum concentration for both rectangular and Hence, from equation  (2), reactant velocity is inversely
trapezoidal flow channels. This confirms the results shown in proportional to cross-sectional area of flow channel. In other
figure 6 (OCV versus methanol concentration). It is found that words, the reactant velocity in trapezoidal flow channels will
the power density obtained in our passive μ-DMFCs is better be higher than that of rectangular cross-sectional geometry.
when compared to other passive DMFCs reported earlier and This implies that due to higher flow velocities in trapezoidal
shown in table 1. flow channels the fuel consumption rate at anode will be
Our design for flow channels in rectangular and trapezoidal higher in trapezoidal flow channels as compared to the one
cross-sections has the same channel length, width and depth. with rectangular cross-sectional flow channels.
But the channel land-width is less for trapezoidal flow chan- Polarization plots in figure  10 indicate that the two flow
nels as compared to that of rectangular flow channels. As a channel geometries have insignificant effect in the low cur­
result, the cross-sectional area of trapezoidal flow channels is rent density region which is the activation polarization region.
less than that of rectangular flow channels as seen in figure 7. Basically, at low current densities the activation polarization
Therefore, the velocity of reactant in trapezoidal flow channels is dominant due to the fact that the electronic barriers are to be
should be higher than in rectangular flow channels for a given overcome before the ionic current flow takes place. Activation
flow rate (25 μl min−1). This can be explained as follows: losses are the main cause for voltage drop in a fuel cell in
Q = v × A
(1) this region [44]. As the current density increases however, the

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J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al

Table 1.  Comparison of power densities of passive DMFCs with


those published in the literature with nafion 117 membrane.
Maximum power Active Flow rate
density (mW cm−2) area (cm2) (μl min−1) Reference
6.64 2.89 25 This worka
3.90 2.89 25 This workb
2 0.18 1.38 [37]
2.45 0.39 1.38 [37]
2.8 0.39 2.76 [37]
3.7 0.39 5.52 [37]
0.29 0.25 0.166 [9]
0.38 2.64 1000 [38]
4.9 1 10 [39]
3.8 4 NS [40]
2.2 4 NS [40]
3.3 9 NS [41]
3 7.5 NS [42]
1.7 1 NS [43]
a
Passive μ-DMFC with trapezoidal cross-sectional flow channels.
b
Passive μ-DMFC with rectangular cross-sectional flow channels.
NS—not specified.

4. Conclusion

We have studied the effect of reactant micro-flow channel cross-


section geometry on the power output of passive μ-DMFCs.
Both rectangular and trapezoidal micro-flow channels were
etched in 〈1 1 0〉 and 〈1 0 0〉 silicon wafer orientations, respec-
tively, by using MEMS fabrication technology. Experiments
were conducted to find the optimal methanol concentration
under passive mode in μ-DMFCs with methanol flow rate of
25 μl min−1 for maximum OCVs at 25 °C. Results showed
an increase in OCV with increase in methanol concentration
with a maximum OCV at 7 M methanol concentration beyond
which OCV dropped significantly for both the μ-DMFCs. It is
Figure 10.  Polarization plots (I–V and I-P curves) of passive
μ-DMFCs with micro-flow channels having, (a) rectangular, and
evident from these results that there is an optimum methanol
(b) trapezoidal cross-sections for various methanol concentrations concentration, 7 M methanol, for passive μ-DMFCs operating
(2 M, 4 M, 6 M, 7 M and 8 M) operated at 25 °C with 25 μl min−1 under passive mode at 25 °C.
methanol flow rate at anode and air-breathing at cathode. We have also studied the effect of rectangular and
trapezoidal cross-sectional geometry of micro-flow chan-
μ-DMFC goes into the ohmic polarization region, and it is nels on power densities of passive μ-DMFC performance
in this region where the passive μ-DMFCs with flow chan- exper­imentally at 25 °C with 2 M, 4 M, 6 M, 7 M and 8 M
nels with trapezoidal cross-sectional geometry give a better methanol concentrations. It was found for the first time that
performance. As mentioned earlier, this is due to the fact the passive μ-DMFCs with trapezoidal flow channels show a
that the flow channels with trapezoidal cross-section result power density enhancement nearly by a factor of two as com-
in higher flow velocities as compared to those with rectan- pared to those with rectangular flow channels. The reason for
gular cross-section as explained using equation  (2). Higher enhanced power output observed in passive μ-DMFCs with
flow velocity essentially implies a higher fuel consumption trapezoidal flow channels is higher reactant flow velocity
[10]. In other words, μ-DMFCs having flow channels with in trapezoidal flow channels as compared to that in rectan-
trapezoidal cross-section result in increased fuel consumption gular flow channels for the same open-ratio, channel length
as compared to those having flow channels with rectangular and depth and with constant flow rate (25 μl min−1); the
cross-section, consequently leading to improved performance enhanced reactant velocity results in higher fuel consump-
in the ohmic polarization region, thereby, leading to improve- tion and hence, improved power density. Though our results
ment in power density nearly by a factor of two. The peak of enhanced power output with trapezoidal flow channels for
power densities were obtained at 7 M methanol concentration flow of optim­ized methanol concentration were obtained with
for passive μ-DMFCs with both rectangular and trapezoidal μ-DMFC as a platform, we believe that they should also be
cross-sections. Hence, 7 M is the optimum methanol concen- applicable to other PEM fuel cells including hydrogen fuel
tration for our design. cells.

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J. Micromech. Microeng. 29 (2019) 075006 A S Rao et al

Acknowledgments analysis in two-phase transport of the passive miniature


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