Review of Most Recent Progress on Development of Polymer Heat Exchangers for Thermal Management Applications

2015 ◽  
Author(s):  
David C. Deisenroth ◽  
Martinus Adrian Arie ◽  
Serguei Dessiatoun ◽  
Amir Shooshtari ◽  
Michael Ohadi ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Thermal Performance ◽  
Heat Exchangers ◽  
High Performance ◽  
Elevated Temperatures ◽  
Polymeric Materials ◽  
Cost Effective ◽  
Polymer Materials ◽  
Manufacturing Cost ◽  
Polymer Heat Exchangers

Polymeric materials have several favorable properties for heat transfer systems, including low weight, low manufacturing cost, antifouling, and anticorrosion. Additionally, polymers are typically electrical insulators, making them favorable for applications in which electrical conductivity is a concern. Examples of utilizing these favorable properties are discussed. The drawbacks to raw polymer materials include low thermal conductivity, low structural strength, and poor stability at elevated temperatures. Methods of mitigating these unfavorable properties, including loading the polymer with other materials and developing new polymers, are discussed. Enhanced geometric designs enabled by additive manufacturing can also improve thermal performance of polymer heat exchangers. Results of a research study utilizing additive manufacturing toward developing high-performance and cost-effective polymer heat exchangers for an air-to-liquid application are reviewed and discussed. Finally, needs for further research on enhancing polymer thermal performance are discussed.

Additive Manufacturing of Nickel-Based Superalloys

2018 ◽  
Author(s):  
Benjamin Graybill ◽  
Ming Li ◽  
David Malawey ◽  
Chao Ma ◽  
Juan-Manuel Alvarado-Orozco ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
High Performance ◽  
Structural Integrity ◽  
Elevated Temperatures ◽  
Secondary Phases ◽  
Treatment Regimens ◽  
Operating Environments ◽  
Manufacturing Technologies

Additive manufacturing enables the design of components with intricate geometries that can be manufactured with lead times much shorter when compared with conventional manufacturing. The ability to manufacture components out of high-performance metals through additive manufacturing technologies attracts industries that wish to develop more complex parts, but require components to maintain their structural integrity in demanding operating environments. Nickel-based superalloys are of particular interest due to their excellent mechanical, creep, wear, and oxidation properties at both ambient and elevated temperatures. However, relationship between process parameters and the resulting microstructure is still not well understood. The control of the microstructure, in particular the precipitation of secondary phases, is of critical importance to the performance of nickel-based superalloys. This paper reviews the additive manufacturing methods used to process nickel-based superalloys, the influence of the process parameters on microstructure and mechanical properties, the effectiveness of various heat treatment regimens, and the addition of particles in order to further improve mechanical properties.

Study on the Heat Transfer Performance of Two Kinds Material for Microstructure Heat Exchanger

2013 ◽  
Vol 712-715 ◽  
pp. 1593-1599
Author(s):  
Jian Zhuang ◽  
Da Ming Wu ◽  
Wei Wang ◽  
Ya Jun Zhang ◽  
Shi Bao Li ◽  
...  
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Heat Transfer Performance ◽  
Cooling Capacity ◽  
Polyphenylene Sulfide ◽  
Polymer Materials ◽  
Manufacturing Cost ◽  
Transfer Performance ◽  
Micro Heat Exchanger ◽  
Metal Materials

In order to verify the possibility that polymer materials for micro heat exchanger could replace metal materials, polymer micro heat exchangers are regarded as the study object. In terms of the experiments and the simulations by Flo EFD software, temperatures, pressures and speeds on micro heat exchanger made by aluminum and conductive plastic Polyphenylene Sulfide (PPS) were carried out analysis respectively. The results showed that the cooling capacities of micro-heat exchangers made by these two materials are quite the same. According to cooling capacity, manufacturing cost and weight, the micro heat exchanger made by conductive plastic is entirely possible to replace the existing metal heat exchanger.

Design and Manufacturing of a Metal 3D Printed kW Scale Axial Turboexpander

2019 ◽  
Author(s):  
Vaclav Novotny ◽  
Monika Vitvarova ◽  
Michal Kolovratnik ◽  
Barbora Bryksi Stunova ◽  
Vaclav Vodicka ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Surface Quality ◽  
High Efficiency ◽  
Cost Effective ◽  
Manufacturing Cost ◽  
Machining Processes ◽  
Manufacturing Method ◽  
Design And Manufacturing ◽  
3D Printed

Abstract Greater expansion of distributed power and process systems based on thermodynamic cycles with single to hundred kW scale power output is limited mainly there are not available cost-effective expanders. Turboexpanders have a perspective of high efficiency and flexibility concerning operating parameters even for the micro applications. However, they suffer from a high manufacturing cost and lead time in the development of traditional technologies (such as casting and machining processes). Additive manufacturing provides a possibility to overcome some of the issues. Manufacturing parts with complicated shapes by this technology, combining multiple components into a single part or rapid production by 3D printing for development purposes are among the prospective features with this potential. On the other hand, the 3D printing processes come with certain limitations which need to be overcome. This paper shows a design and manufacturing process of a 3 kW axial impulse air turbine working with isenthalpic drop 30 kJ/kg. Several samples to verify printing options and the turbine itself has been manufactured from stainless steel by the DMLS additive manufacturing method. Manufactured are two turbine variations regarding blade size and 3D printer settings while maintaining their specific dimensions. The turboexpanders testing method and rig is outlined. As the surface quality is an issue, several methods of post-processing of 3D printed stator and rotor blading to modify surface quality are suggested. Detailed experimental investigation is however subject of future work.

Characterization of Highly Thermally Conductive Organic Substrates for a Double-Sided Cooled Power Module

2020 ◽  
Vol 2020 (1) ◽  
pp. 000277-000281
Author(s):  
Tzu-Hsuan Cheng ◽  
Kenji Nishiguchi ◽  
Yoshi Fukawa ◽  
B. Jayant Baliga ◽  
Subhashish Bhattacharya ◽  
...  
Keyword(s):  
Thermal Performance ◽  
High Performance ◽  
Resin Composite ◽  
Cost Effective ◽  
Organic Substrates ◽  
Power Module ◽  
Epoxy Resin Composite ◽  
Thermally Conductive ◽  
Low Modulus

Abstract Silicon-Carbide (SiC) power devices have become a promising option for traditional Silicon (Si) due to the superior material properties. To fully take advantage of the SiC devices, a high-performance power device packaging solution is necessary. This study proposes a cost-effective double-sided cooled (DSC) 1.2 kV SiC half-bridge power module using organic epoxy-resin composite dielectric (ERCD) substrates. The high mechanical and thermal performance of the power module is achieved by the low-modulus, moderate thermal conductivity, and relatively thin (120 μm) layer of ERCD material compared with traditional metal-clad ceramic approaches. This novel organic dielectric can withstand high voltage (5 kV @ 120 μm) and operate up to 250°C continuously, which is indispensable for high power applications. The thermal modeling results show that the equivalent thermal resistance junction-to-case (Rjc_eq) of the DSC power module using dual direct bonded copper (DBC) is 17% higher than the dual ERCD configuration. Furthermore, a non-insulated DSC power module concept is proposed for maximizing thermal performance by considering thermal vias in the ERCD substrate and direct-soldered heat sink. A thought process for optimization of thermal via design is demonstrated and it shows up to 24% of improvement on thermal performance compared with the insulated DSC power module.

Using CFD Simulations to Improve the Air-Cooled Steam Condenser Performance in Severe Windy Conditions via Proper Tuning of Blades Pitch Angles

2018 ◽  
Author(s):  
Masoud Darbandi ◽  
Hamid Reza Khorshidi Behzadi ◽  
Vahid Farhangmehr ◽  
Gerry E. Schneider
Keyword(s):  
Heat Transfer ◽  
Thermal Performance ◽  
Heat Exchangers ◽  
Power Plants ◽  
Thermal Power ◽  
Research Work ◽  
Convection Heat Transfer ◽  
Heat Rate ◽  
Cost Effective ◽  
Cold Air

The use of air-cooled steam condenser (ACSC) in thermal power plants has become so normal since a few decades ago. It is because there are so many valuable advantages with the ACSC implementation, e.g., little dependency on water consumption and benefiting from the forced convection heat transfer instead of the natural one to condense the steam. However, the thermal performance of an ACSC can be readily defected by the ambient wind; specifically, when the ambient temperature is high. This research work benefits from the computational fluid dynamics tool to study the details of ACSC’s thermal performance in such undesirable ambient windy conditions. Furthermore, this work suggests an effective remedy to increase the heat rate from the proposed ACSC. Evidently, the flow rate of cold air through the heat exchangers of proposed ACSC has direct influence in heat transfer rate from the heat exchangers of ACSC. One remedy to achieve higher cold air flow rates through these heat exchangers is to improve the design of its fans or blowers. However, for an ACSC already in service, one should look for other cost-effective remedies. So, if one wishes to improve the performance of those fans without changing their design one should pay attention to some other simple ways with little costs to implement them. This work suggests to tune up the pitch angles of blades of ACSC’s fans properly. The details of implementing this remedy are presented in this paper.

Polymeric Hollow Fiber Heat Exchangers (PHFHEs): A New Type of Compact Heat Exchanger for Lower Temperature Applications

2005 ◽  
Author(s):  
Dimitrios M. Zarkadas ◽  
Baoan Li ◽  
Kamalesh K. Sirkar
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Thermal Performance ◽  
Hollow Fiber ◽  
Heat Exchangers ◽  
Operating Cost ◽  
Polymer Materials ◽  
Steam Condensation ◽  
New Type ◽  
Shell And Tube

Plastic heat exchangers are characterized by an inferior thermal performance compared to their metal counterparts. Therefore, their usage is mainly limited to handling corrosive media or when ultra high purity is required, e.g., pharmaceutical industry. Polymeric Hollow Fiber Heat Exchangers (PHFHEs) have recently been proposed [1] as a new type of heat exchanger that can overcome these constraints and offer the same or better thermal performance than metallic shell and tube or plate heat exchangers while occupying a much smaller volume. In this paper we report our results for heat transfer in PHFHEs with both parallel and cross flow in the shell side of the device. Fibers made of polypropylene (PP) and polyetheretherketone (PEEK) were tested. In addition, steam condensation studies in PHFHEs are reported for the first time. The overall heat transfer coefficients achieved for water-water and water-brine systems are as high as 1400 Wm−2K−1. These values are higher than any value reported for plastic heat exchangers and comparable with commonly acceptable design values for metal shell and tube heat exchangers. Similar coefficients were obtained for steam condensation. Polymeric hollow fiber heat exchangers can also achieve high thermal effectiveness, large number of transfer units (NTU) and very small height of a transfer unit (HTU), if properly rated. If designed like commercial membrane contactors, they can achieve up to 12 transfer units in a single device, not longer than 60–70 cm! In addition, the conductance per unit volume PHFHEs achieved was up to one order of magnitude higher compared to metal heat transfer equipment. This superior thermal performance is also accompanied by considerably lower pressure drops. Therefore, the operation of PHFHEs will be characterized by a low operating cost. Combined with the much lower cost, lower weight and elimination of metal contamination polymer materials offer, it is obvious that PHFHEs constitute a potential substitute for metal heat exchangers on both thermal performance and economical grounds. Possible application fields include the food, pharmaceutical and biomedical industries as well as applications where corrosion resistant, light and very efficient devices are required, i.e., desalination, solar and offshore heat transfer applications.

Experimental Investigation of a Cost Effective Skived Microchannel Cold Plate for Mass Production

2015 ◽  
Author(s):  
Mark E. Steinke ◽  
Vinod Kamath
Keyword(s):  
Thermal Resistance ◽  
Thermal Performance ◽  
Cost Effective ◽  
Thin Layers ◽  
Warm Water ◽  
Working Fluid ◽  
Manufacturing Cost ◽  
Cold Plate ◽  
Ambient Temperatures ◽  
And Performance

A liquid cold plate that utilizes skived microchannels has been developed to gain the benefits of direct liquid cooling, but minimize the expensive cost of such cold plates. The construction, application, and experimental results of the skived cold plate will be presented. Skiving is a mechanical process that cuts thin layers of material. It is an established process for making air cooled heat sinks. In this application, the fin field is skived and placed inside a housing that allows for liquid flow through the resulting fins. The design boundary conditions and parameters will be described and performance per cost metric will be presented and used to evaluate future optimization possibilities. The objective of the present work was to minimize the thermal resistance while maintaining a low manufacturing cost. The design goal was to produce a cold plate that had sufficient thermal performance and the ability to be mass produced at a reasonable cost. The resulting cold plate would also need to support warm water cooling of microprocessors. Warm water is a working fluid that has not been chilled below ambient temperatures. Therefore, the water temperature could be up to 45 degrees Celsius. The cold plate had a thermal resistance less than 0.3 °Ccm2/W. The pressure drop was minimized to lower the required pumping power and was less than 6 kPa at 1.0 liter per minute. Using a skiving process, it is possible to develop a cold plate that delivers good thermal performance and maintains a low production cost.

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