Search Results (38)

The escalating heat flux densities in high-performance electronics necessitate superior thermal management. This study enhanced pool-boiling heat transfer, a method offering high heat removal capacity, by leveraging Binder Jetting 3D Printing (BJ3DP) to create complex porous copper structures without the need for chemical treatments. This approach enables a reliable utilization of phenomena like capillarity for improved performance. Three types of porous copper structures, namely Large Lattice, Small Lattice, and Staggered, were fabricated on pure copper substrates and tested via pool boiling of de-ionized and de-gassed water at atmospheric pressure. Compared to a plain polished copper surface, which exhibited a critical heat flux (CHF) of 782 kW/m² at a wall superheat of 18 K, the 3D-printed porous copper surfaces showed significantly improved heat transfer performance. The Staggered surface achieved a conventional CHF of 2342.4 kW/m² (a 199.7% enhancement) at a wall superheat of 24.6 K. Notably, the Large Lattice and Small Lattice structures demonstrated exceptionally stable boiling without reaching the typical catastrophic CHF within the experimental parameters. These geometries continued to increase in heat flux, reaching maximums of 2397.7 kW/m² (206.8% higher at a wall superheat of 55.6 K) and 2577.2 kW/m² (229.7% higher at a wall superheat of 39.5 K), respectively. Subsequently, a gradual decline in heat flux was observed with an increasing wall superheat, demonstrating an outstanding resistance to the boiling crisis. These improvements are attributed to the formation of distinct vapor–liquid pathways within the porous structures, which promotes the efficient rewetting of the heated surface through capillary action. This mechanism supports a highly efficient, self-sustaining boiling configuration, emphasizing the superior rewetting and vapor management capabilities of these 3D-printed porous structures, which extend the boundaries of sustained high heat flux performance. The porous surfaces also demonstrated a higher heat transfer coefficient (HTC), particularly at lower heat fluxes (≤750 kW/m²). High-speed digital camera visualization provided further insight into the boiling phenomenon. Overall, the findings demonstrate that these BJ3DP structured surfaces produce optimized vapor–liquid pathways and capillary-enhanced rewetting, offering significantly superior heat transfer performance compared to smooth surfaces and highlighting their potential for advanced thermal management. Full article

Polymer heat exchangers (HXs) are lightweight and cost-effective due to the affordability of raw polymer materials. However, the inherently low thermal conductivity (TC) of polymers limits their application in HXs. To enhance thermal conductivity polymer composites, two types of diamond powders, with particle sizes of 0.25 µm and 16.7 µm, were used as fillers, while Acrylonitrile Butadiene Styrene (ABS) served as the matrix. Composite polymer samples were fabricated, and their density and thermal conductivity were tested and compared. The results indicate that fillers with larger particle sizes tend to exhibit higher thermal conductivity. A polymer HX based on a Triply Periodic Minimal Surface (TPMS) structure was designed. The factors influencing the efficiency of polymer HXs were analyzed and compared with those of metal HXs. In polymer HXs, the polymer wall is the primary source of heat resistance. Additionally, the mechanical strength of 3D-printed polymer parts was evaluated. Finally, an HX was successfully fabricated using a polymer composite containing 50 wt% diamond powder via 3D printing. Full article

This study describes experimental data on 3D-printed compact heat exchangers. The heat exchanger is a prototype designed and manufactured additively using 3D printing in metal—AISI 316L steel. The device’s design is based on the triply periodic minimal surface (TPMS) geometry called gyroid, which can only be obtained by incremental manufacturing. This innovative heat exchange surface structure enables these devices to provide higher thermal performance while reducing their weight by up to 50%. Few publications describe thermal or flow tests in this type of device. They mainly concern computer simulations that have yet to be experimentally verified. The authors of this study conducted innovative flow tests to determine pressure drops during the flow of working fluids under conditions of variable temperature, mass flow rate and thermal load. Water was used as a heat transfer fluid during the tests. The range of parameters for the entire experiment was ṁ = 1–24 kg/h; Δp/Δl = 0.05–2 kPa; t_cold = 20 °C; t_hot = 50 °C. Flow characteristics during the single-phase heat exchange process were determined, including Δp/Δl = f(ṁ), Δp/Δl = f(Re), Δp/Δl = f(f). The experimental data will be used to determine the relationships describing flow resistance in structures based on a triply periodic minimal surface, and it also enables one to specify the energy consumption of these devices and compare the profitability of their use to conventional designs, i.e., shell-and-tube or plate heat exchangers. Full article

This study investigates the thermal performance of various counterflow air-to-air heat exchangers under unbalanced flow conditions, aiming to enhance the efficiency of heat recovery systems. Mechanical ventilation with heat recovery is critical in energy-efficient buildings to reduce heat loss, which can reach up to 60% in air exchange processes. This research focuses on the effects of flow imbalance on the heat transfer efficiency of three specific heat exchangers: two commercially available models (Recair Sensitive RS160 and Core ERV366) and a custom 3D-printed prototype (GV PROTO). Experimental tests measured temperature efficiency under both balanced and unbalanced flow conditions, with results indicating that flow imbalance significantly impacts thermal efficiency. Among the exchangers, the RS160 displayed the highest temperature efficiency, maintaining performance better than the others as flow rates increased. The results of the study show that even small differences in the thermal efficiency of different heat exchangers under balanced airflow conditions transform into significant differences under unbalanced conditions. These findings contribute to a better understanding of how real-world ventilation imbalances affect heat exchanger performance, offering insights to optimize energy efficiency in ventilation systems. Full article

This article presents the development of a resistive frost-detection sensor fabricated using Fused Filament Fabrication (FFF) with a conductive filament. This sensor was designed to enhance demand-defrost control in industrial refrigeration systems. Frost accumulation on evaporator surfaces blocks airflow and creates a thermal insulating barrier that reduces heat exchange efficiency, increasing energy consumption and operational costs. Traditional timed defrosting control methods can mitigate these effects but often lead to inefficiencies due to their inability to align with actual frost accumulation, which can vary according to system and environmental conditions. Frost-detection sensors aim to solve this problem by acting as a tool to support defrosting control. A series of tests were conducted to evaluate the sensor’s performance in detecting frost under controlled conditions on a heat exchanger (HX). The sensor reliably detected frost in all cases, demonstrating its effectiveness in real-time frost detection. The sensor measurements were validated by comparison with results obtained through a computer vision method, confirming its reliability. It was also found that the sensor can detect temperature changes. This advancement in sensor technology highlights the potential of additive manufacturing to provide cost-effective, customizable, replicable, and compact sensor designs, contributing to improved system performance and energy efficiency in refrigeration systems. Full article

In recent years, additive manufacturing has reached the required reliability to effectively compete with standard production techniques of mechanical components. In particular, the geometrical freedom enabled by innovative manufacturing techniques has revolutionized the design trends for compact heat exchangers. Bioinspired structures, such as the gyroid lattice, have relevant mechanical and heat exchange properties for their light weight and increased heat exchange area, which also promotes the turbulent regime of the coolant. This work focuses its attention on the effect of the relevant design parameters of the gyroid lattice on heat exchange performances. A numerical comparative analysis is carried out from the thermal and fluid dynamic points of view to give design guidelines. The results of numerical analyses, performed on cylindrical samples, are compared to the experimental results on the pressure drop. Lattices samples were successfully printed with material extrusion, which is a low-cost and easy-to-use metal AM technology. For each lattice sample, counter pressure, heat exchange, and turbulence intensity ratio are calculated from the numerical point of view and discussed. At the end, the gyroid lattice is proven to be very effective at enhancing the heat exchange in cylindrical pipes. Guidelines are given about the choice of the best lattice, depending on the considered applications. Full article

The study describes experimental data on thermal tests during the condensation of HFE7100 refrigerant in a compact heat exchanger. The heat exchanger was manufactured using the additive 3D printing in metal. The material is AISI 316L steel. MPCM slurry was used as the heat exchanger coolant, and water was used as the reference medium. The refrigerant was condensed on a bundle of circular tubes made of steel with an internal/external diameter of d_i/d_e = 2/3 mm, while a mixture of water and phase change materials as the coolant flowed through the channels. Few studies consider the heat exchange in condensation using phase change materials; furthermore, there is also a lack of description of heat exchange in small-sized exchangers printed from metal. Most papers deal with computer research, including flow simulations of heat exchange. The study describes the process of heat exchange enhancement using the phase transition of coolant. Experimental data for the mPCM slurry coolant flow was compared to the data of pure water flow as a reference liquid. The tests were carried out under the following thermal and flow conditions: G = 10–450 [kg m−² s⁻¹], q = 2000–25,000 [W m⁻²], and t_s = 30–40 [°C]. The conducted research provided many quantities describing the heat exchange in compact heat exchangers, including heat exchanger heat power, heat exchange coefficient, and heat exchange coefficients for working media. Based on these factors, the thermal performance of the heat exchanger was described. External characteristics include the value of the thermal power and the heat exchange coefficient as a function of the mass flow density of the working medium and the average logarithmic temperature difference. The performance of the heat exchanger was presented as the dependencies of the heat exchange coefficients on the mass flux density and the heat flux density on the heat exchange surface. The thickness of the refrigerant’s condensate film was also determined. Furthermore, a model was proposed to determine the heat exchange coefficient value for the condensing HFE7100 refrigerant on the outer surface of a bundle of smooth tubes inside a compact heat exchanger. According to experimental data, the calculation results were in good agreement with each other, with a range of 25%. These data can be used to design mini condensers that are widely used in practice. Full article

In just a few short years, the additive manufacturing (AM) technology known as 3D printing has experienced intense growth from a niche technology to a disruptive innovation that has captured the imagination of mainstream manufacturers and hobbyists alike. The purpose of this article is to introduce the use of 3D printing for specific applications, materials, and manufacturing processes that help to optimize heat transfer in heat exchangers, with an emphasis on sustainability. The ability to create complex geometries, customize designs, and use advanced materials provides opportunities for more efficient and stable heat transfer solutions. One of the key benefits of incremental technology is the potential reduction in material waste compared to traditional manufacturing methods. By optimizing the design and structure of heat transfer components, 3D printing enables lighter yet more efficient solutions and systems. The localized manufacturing of components, which reduces the need for intensive transportation and associated carbon emissions, can lead to reduced energy consumption and improved overall efficiency. The customization and flexibility of 3D printing enables the integration of heat transfer components into renewable energy systems. This article presents the key challenges to be addressed and the fundamental research needed to realize the full potential of incremental manufacturing technologies to optimize heat transfer in heat exchangers. It also presents a critical discussion and outlook for solving global energy challenges through innovative incremental manufacturing technologies in the heat exchanger sector. Full article

Triply periodic minimal surface (TPMS) heat exchangers (HXs) have been investigated in this paper along with additive manufacturing (AM). Heat transfer coefficients, pressure drops, and thermal capacity were systematically evaluated as functions of wall thickness, lattice cell density, and materials. It turns out that when thermal conductivity is above 100 W/m·K, gyroid HXs are less sensitive to variations in thickness and thermal conductivity. Additive manufacturing of 20 kW aluminum heat exchangers was successful and testing results are comparable with theoretical prediction. To the best of our knowledge, this is the first demonstration of a working prototype of TPMS HXs. Full article

The concentration of residual O₂ in oxy-fuel combustion flue gas needs to be reduced before CO₂ transportation, utilization, or storage. An original application of the printed circuit heat exchanger (PCHE) for catalytic combustion with natural gas (catalytic deoxygenation) is described for reducing the residual O₂ concentration. The PCHE design features multiple adiabatic packed beds with interstage cooling and fuel injection, allowing precise control over the reaction extent and temperature within each reaction stage through the manipulation of fuel and utility flow rates. This work describes the design of a PCHE for methane–oxygen catalytic combustion where the catalyst loading is minimized while reducing the O₂ concentration from 3 vol% to 100 ppmv, considering a maximum adiabatic temperature rise of 50 °C per stage. Each PCHE design differs by the number of reaction stages and its individual bed lengths. As part of the design process, a one-dimensional transient reduced-order reactor model (1D ROM) was developed and compared to temperature and species concentration axial profiles from 3D CFD simulations. The final design consists of five reaction stages and four heat exchanger sections, providing a PCHE length of 1.09 m at a processing rate of 12.3 kg/s flue gas per m³ PCHE. Full article

This literature review indicates that the basic microstructure of Ti6Al4V is bimodal, consisting of two phases, namely α + β, and it occurs after fabrication using conventional methods such as casting, plastic forming or machining processes. The fabrication of components via an additive manufacturing process significantly changes the microstructure and properties of Ti6Al4V. Due to the rapid heat exchange during heat treatment, the bimodal microstructure transforms into a lamellar microstructure, which consists of two phases: α′ + β. Despite the application of optimum printing parameters, 3D printed products exhibit typical surface defects and discontinuities, and in turn, surface finishing using shot peening is recommended. A literature review signalizes that shot peening and electropolishing processes positively impact the corrosion behavior, the mechanical properties and the condition of the surface layer of conventionally manufactured titanium alloy. On the other hand, there is a lack of studies combining shot peening and electropolishing in one hybrid process for additively manufactured titanium alloys, which could synthesize the benefits of both processes. Therefore, this review paper clarifies the effects of shot peening and electropolishing treatment on the properties of both additively and conventionally manufactured Ti6Al4V alloys and shows the effect process on the microstructure and properties of Ti6Al4V titanium alloy. Full article

Lattice structures such as triply periodic minimal surface (TPMS) structures have gained significance due to advancements in additive manufacturing, particularly 3D printing, which enable their engineering to be tailored to specific applications, such as heat exchangers. While traditional heat exchanger designs have been extensively studied, investigations into the thermal performance of TPMS structures are limited. Considering the extensive range of the geometric design variations in TPMS structures, highly efficient structures on par with the performance of conventional heat exchanger designs can be expected. This study aims to comprehensively evaluate the thermal and flow characteristics of a specific TPMS structure (Fischer Koch S), and, in particular, the impact of various volume fractions on its heat transfer performance and on its friction factor. Another key objective of this study is to develop Nusselt and friction factor correlations as a function of the investigated volume fractions for potential use in future design tools. To this end, a broad CFD study was carried out. Additionally, this study provides insights into the procedures involved in generating Fischer Koch S geometries and the modeling methodology employed in CFD investigations. Based on the results of the CFD study, the thermal and fluid dynamic performances of Fischer Koch unit cells were evaluated, resulting in heat transfer coefficients up to 160 W/m²K for the investigated structures. A comparison between the heat transfer coefficient of the examined TPMS structure and a conventional plate heat exchanger suggested a potential increase in the heat transfer coefficient of approximately 35%. The generated CFD data were subsequently utilized to formulate fitting correlations for the Nusselt number and friction factors as a function of the volume fraction. The fitted parameters of these correlations are provided in this work. Full article

As electronic components progressively downsize and their power intensifies, thermal management has emerged as a paramount challenge. This study presents a novel, high-efficiency finned heat exchanger, termed Flat-Plate Oscillating Heat Pipe Finned Radiator (FOHPFR), which employs arrayed flat-plate oscillating heat pipes (OHP) as heat dissipation fins. Three-dimensional (3D)-printed techniques allow the internal microchannels of the FOHPFR to become rougher, providing excellent surface wettability and capillary forces, which in turn significantly improves the device’s ability to dissipate heat. In this study, the 3D-printed FOHPFR is compared with traditional solid finned radiators made of identical materials and designs. The impacts of filling ratio, inclination angle, and cold-end conditions on the heat transfer performance of the 3D-printed FOHPFR are investigated. It is demonstrated by the results that compared to solid finned radiators, the FOHPFR exhibits superior transient heat absorption and steady-state heat transfer capabilities. When the heating power is set at 140 W, a decrease in thermal resistance from 0.32 °C/W in the solid type to 0.11 °C/W is observed in the FOHPFR, marking a reduction of 65.6%. Similarly, a drop in the average temperature of the heat source from 160 °C in the solid version to 125 °C, a decrease of 21.8%, is noted. An optimal filling ratio of 50% was identified for the vertical 3D-printed FOHPFR, with the minimal thermal resistance achieving 0.11 °C/W. Moreover, the thermal resistance of the 3D-printed FOHPFR is effectively reduced compared to that of the solid finned radiator at all inclination angles. This indicates that the FOHPFR possessed notable adaptability to various working angles. Full article

Thermal management devices such as heat exchangers and heat pipes are integral to safe and efficient performance in multiple engineering applications, including lithium-ion batteries, electric vehicles, electronics, and renewable energy. However, the functional designs of these devices have until now been created around conventional manufacturing constraints, and thermal performance has plateaued as a result. While 3D printing offers the design freedom to address these limitations, there has been a notable lack in high thermal conductivity materials beyond aluminium alloys. Recently, the 3D printing of pure copper to sufficiently high densities has finally taken off, due to the emergence of commercial-grade printers which are now equipped with 1 kW high-power lasers or short-wavelength lasers. Although the capabilities of these new systems appear ideal for processing pure copper as a bulk material, the performance of advanced thermal management devices are strongly dependent on topology-optimised filigree structures, which can require a very different processing window. Hence, this article presents a broad overview of the state-of-the-art in various additive manufacturing technologies used to fabricate pure copper functional filigree geometries comprising thin walls, lattice structures, and porous foams, and identifies opportunities for future developments in the 3D printing of pure copper for advanced thermal management devices. Full article

The rapid evolution of electric machines requires innovative approaches to boost performance, efficiency, and sustainability. Additive Manufacturing (AM) has emerged as a transformative technique, reshaping the landscape of electric machine components, ranging from magnetic materials to windings and extending to thermal management. In the area of magnetic materials, AM’s capacity to fabricate intricate structures optimizes magnetic flux dynamics, yielding advanced shape-profile cores and self-coating laminations for superior performance. In windings, AM’s prowess is evident through innovative concepts, effectively mitigating AC conduction effects while reducing weight. Furthermore, AM revolutionizes thermal management, as exemplified by 3D-printed ceramic heat exchangers, intricate cooling channels, and novel housing designs, all contributing to enhanced thermal efficiency and power density. The integration of AM not only transcends conventional manufacturing constraints but also promises to usher in an era of unprecedented electric machine innovation, addressing the intricate interplay of magnetic, winding, and thermal dynamics. Full article