Search Results (165)

To meet the miniaturized cooling demands of high-heat-flux electronic devices, metal foams—featuring high specific surface area and multiscale porous structures—are considered promising candidates for enhancing flow boiling evaporation. However, pore density (PPI) and grooved geometry (channel aspect ratio, AR) jointly regulate vapor–liquid distribution, rewetting, and flow resistance, thereby constraining overall performance. Here, flow boiling experiments were conducted on nickel and copper foams with pore densities of 100, 500, and 1000 PPI and AR values of 0.7, 1.0, and 1.3. Heat transfer coefficient (HTC), wall superheat ($\mathsf{\Delta }T$), and pressure drop ($\mathsf{\Delta }p$) were systematically evaluated, complemented by transient two-phase simulations revealing vapor fraction, temperature, and pressure drop distributions. A pronounced non-monotonic pore-density dependence is observed: 500 PPI achieves an optimal balance between heat-transfer enhancement and flow resistance, whereas 100 PPI suffers from vapor accumulation and temperature non-uniformity, and 1000 PPI is penalized by excessive permeability resistance and pore-scale confinement. An optimal AR of 1.0 promotes efficient vapor venting and stable rewetting. Under the optimal configuration (500 PPI, AR $=1.0$), a limiting heat flux of 348.6 W/cm², corresponding to the HTC of 55.4 kW/(m² · K), and a limiting HTC of 130.3 kW/(m² · K) are achieved, providing quantitative design guidelines for metal-foam two-phase evaporators. Full article

Water pollution from industrial dyes is a critical challenge due to the resistance of these types of compounds to degradation and potentially harmful effects on living organisms and human health. In this study, the electrochemical degradation of methylene blue (MB) was investigated using ink-based copper foam electrodes with reduced graphene oxide (rGO), antimony trioxide (Sb₂O₃), and rGO/Sb₂O₃ composites. The materials used to synthesize the electrodes were characterized by X-ray diffraction (XRD), which showed the successful synthesis of GO, rGO, and the Sb₂O₃-rGO composite. Additionally, the synthesized electrodes were examined using SEM. The MB degradation was studied using kinetic behavior and removal efficiency at pH levels from 3 through 6, monitored using UV-Vis spectroscopy. The electrocatalytic degradation was studied using sodium sulfate as the electrolyte across a pH range of 3 to 8. All electrodes investigated were determined to follow first-order kinetics. The Sb₂O₃-rGO composite showed the highest rate constants of MB degradation at pH 7 and 8, with rate constants of 0.0160 and 0.0159 min⁻¹, respectively. At the same time, the rGO ink-based electrode worked fastest at pH 3 and pH 4 with rate constants of 0.0178 and 0.0158 min⁻¹, respectively. The Sb₂O₃ also works best at pH 3 and 4 with rate constants of 0.0151 and 0.0152 min⁻¹. SEM analysis shows the composite electrode was more resilient to degradation than other materials. Full article

Frother chemistry strongly influences gas dispersion, froth stability, water recovery, and selectivity in flotation circuits; however, conventional frothers may exhibit excessive persistence and partitioning under alkaline conditions, impairing downstream cleaning performance. This study evaluates a novel switchable frother chemistry (Transfoamer^TM) designed to achieve the benefits of strong frothing in the rougher stage while reducing the selectivity losses associated with high frother concentrations in the cleaner stages. Laboratory column tests, batch flotation experiments, and an industrial evaluation at the Caserones concentrator were conducted to characterize frother behavior in terms of gas holdup, foam height, water carrying rate, and persistence. The results showed that the Transfoamer^TM behaved as a strong frother under mildly alkaline conditions, providing gas dispersion comparable to conventional strong frothers. As pH increased, a distinct switching behavior was observed, characterized by reduced gas holdup, foam height, water recovery, and persistence, in contrast to traditional alcohol- and polyglycol-type frothers. Batch flotation tests and plant trials confirmed that combining MIBC with Transformer^TM T-100 improved rougher copper recovery without compromising circuit selectivity. Full article

Residential space heating in Northern Europe requires long-duration thermal storage to align summer solar gains with winter heating demand. This study investigates a compact sand-based seasonal thermal energy storage integrated with flat-plate solar collectors for an A+ class single-family house in Kaunas, Lithuania. An iterative co-design couples collector sizing with the seasonal charging target and a 3D COMSOL Multiphysics model of a 300 m³ sand-filled, phenolic foam-insulated system, with a 1D conjugate model of a copper pipe heat-exchanger network. The system was charged from March to September and discharged from October to February under measured-weather boundary conditions across three consecutive annual cycles. During the first year, the storage supplied the entire winter heating demand, though 35.2% of the input energy was lost through conduction, resulting in an end-of-cycle average sand temperature slightly below the initial state. In subsequent years, both the peak sand temperature and the residual end-of-cycle temperature increased by 3.7 °C and 3.2 °C, respectively, by the third year, indicating cumulative thermal recovery and improved retention. Meanwhile, the peak conductive losses rate decreased by 98 W, and cumulative annual losses decreased by 781.4 kWh in the third year, with an average annual reduction of 4.15%. These results highlight the progressive self-conditioning of the surrounding soil and demonstrate that a low-cost, sand-based storage system can sustain a complete seasonal heating supply with declining losses, offering a robust and scalable approach for residential building heating applications. Full article

Copper-based electrocatalytic materials with high surface area are essential for various processes, such as water splitting and the electroreduction of carbon dioxide and nitrates. Three-dimensional nanostructured electrodes offer distinct advantages in these applications due to their expansive surface area, which enhances charge transfer and mass transport. For bimetallic systems, however, the phase state, whether a solid solution or a mechanical mixture of metals, is critically important for catalytic performance. This study explores the formation of Cu-Ni solid solutions via electrodeposition using the dynamic hydrogen bubble template method. Two types of electrolyte were employed: sulfate-based and citrate-based. Through characterization by X-ray diffraction, scanning electron microscopy, elemental mapping, and X-ray fluorescence spectroscopy, we demonstrate that metallic foams deposited from sulfate solutions are heterogeneous, with poor control over nickel content. In contrast, the use of citrate-based solutions allows the nickel content in the deposits to be effectively controlled by varying the solution composition, thereby enabling the formation of a solid solution. Full article

Precise segmentation of flotation froths is a critical bottleneck to achieving intelligent perception and optimal control of process operations. Traditional convolutional neural networks (CNNs) are inherently limited by local receptive fields, making it challenging to accurately segment adhesive and multi-scale froths. To address this fundamental issue, this paper proposes a deep segmentation network with integrated global context awareness, termed GC-FSegNet, which establishes a new paradigm capable of jointly modeling macro-level structures and micro-level details. The proposed GC-FSegNet innovatively integrates the Global Context Network (GCNet) module into both the encoder and decoder of a Nested U-Net architecture. The GCNet captures long-range dependencies between froths, enabling macro-level modeling of clustered foam structures, while the Nested U-Net preserves high-resolution boundary details. Through their synergistic interaction, the model achieves simultaneous and efficient representation of both global contours and local details of froth images. Furthermore, the Mish activation function is employed to enhance the learning of weak boundary features, and a combined Dice and Binary Cross-Entropy (BCE) loss function is designed to optimize boundary segmentation accuracy. Experimental results on a self-constructed copper–lead flotation froth dataset demonstrate that GC-FSegNet achieves an mDice of 0.9443, mIoU of 0.8945, mRecall of 0.9866, and mPrecision of 0.9705, significantly outperforming mainstream models such as U-Net and DeepLabV3+. This study not only provides a reliable technical solution for high-adhesion froth segmentation but, more importantly, introduces a promising “global–local collaborative modeling” framework that can be extended to a wide range of complex industrial image segmentation scenarios. Full article

Ensuring efficient heat transfer to maintain optimal system performance is crucial in modern electronics owing to the rise of artificial intelligence. In the last few decades, scholars have explored various strategies for enhancing electronic device thermal management, focusing on the effects of fin shape, dimension, and spacing on heat transfer efficiency. Recent advancements in additive manufacturing have enabled fabrication of complex geometries, such as triply periodic minimal surfaces (TPMSs), which represent promising alternatives to conventional designs. This study presents a comparative analysis of the thermal performance and fluid flow characteristics of two foam TPMS-based (gyroid and primitive) heat sinks with wavy fins made using aluminum foam. COMSOL Multiphysics version 5.1, employed along with the implemented finite element method, was used to simulate convective heat transfer, pressure drop, the Nusselt number, and thermal performance at different fluid velocities along the length of a channel. The foam structure was heated by a copper plate, and the Nusselt number was evaluated over porosity levels from 0.1 to 0.9. A porosity between 0.5 and 0.7 offers the best balance of cooling performance and pumping power. Foam TPMS heat sinks, particularly those with a gyroid structure, provide enhanced thermal dissipation owing to their high surface area-to-volume ratio and interconnected geometry. Our findings confirm that TPMS heat sinks have promising potential for use as alternatives to conventional wavy designs for advanced thermal management applications. Full article

Thermosyphon heat pipes (THPs) are increasingly employed in advanced thermal management applications due to their highly effective thermal conductivity, compact design, and passive operation. In this study, a numerical investigation was conducted on a copper or aluminum thermosyphon charged with different working fluids, with methanol serving as a reference case. A two-dimensional compressible CFD model was implemented in OpenFOAM, coupling the Volume of Fluid (VOF) method with a hybrid phase-change formulation that integrates the Lee and Tanasawa approaches. It provides, indeed, a balance between computational efficiency and physical fidelity. The vapor flow, considered as an ideal gas, was assumed compressible. The isoAdvector algorithm was applied as a reconstruction technique in order to improve interface capturing, to reduce spurious oscillations and parasitic currents, and to ensure more realistic simulation of boiling and condensation phenomena. The performance dependency on operating parameters such as the inclination angle, liquid filling ratio, and thermophysical properties of the working fluid is analyzed. The numerical predictions were validated against experimental measurements obtained from a dedicated test bench, showing discrepancies below 3% under vertical operation. This work provides new insights into the coupled influence of orientation, fluid inventory, and working fluid properties on THP behavior. Beyond the experimental validation, it establishes a robust computational framework for predicting two-phase heat and mass transfer phenomena by linearizing and treating the terms involved in thebalances to be satisfied implicitly. The results reveal a strong interplay between the inclination angle and filling ratio in determining the overall thermal resistance. At low filling ratios, the vertical operation led to insufficient liquid return and increased resistance, whereas inclined orientations enhanced the liquid spreading and promoted more efficient evaporation. An optimal filling ratio range of 40–60% was identified, minimizing the thermal resistance across the working fluids. In contrast, excessive liquid charge reduced the vapor space and degraded the performance due toflow restriction and evaporationflooding. Full article

Ensuring thermal stability is a major concern in lithium-ion battery systems. Although phase change materials (PCMs) provide a passive approach for temperature regulation, they are limited by poor heat conduction and potential leakage during phase transitions. This study develops a novel composite PCM (CPCM) using paraffin (PA) as the matrix, copper foam (CF) as a conductive skeleton (10–30 pores per inch, PPI), and a low-melting-point alloy (LMA) as an encapsulant to prevent leakage. The effects of CF pore size on thermal conductivity, impregnation ratio, and leakage resistance were systematically investigated. Results show that CPCM with 10 PPI CF achieved the highest thermal conductivity (4.42 W·m⁻¹·K⁻¹), while LMA encapsulation effectively eliminated leakage. The thermal management performance was evaluated on both a single 18,650 LIB cell and a 2S2P module during rate discharging at 1C, 2C, and 3C. For the module at 3C, the 10 PPI CPCM significantly lowered the maximum temperature from 75.9 °C to 44.6 °C and critically reduced the maximum temperature difference between cells from 10.2 °C to a safe level of 1.2 °C, significantly improving temperature uniformity. This work provides a high-conductivity and leakage-proof CPCM solution based on LMA-encapsulated CF/PA for enhanced thermal safety and uniformity in LIB modules. Full article

This work reports the fabrication of innovative flexible conductive polymer composites (FCPCs), composed of poly (2,3-dihydrothieno-1,4-dioxin)-poly (styrenesulfonate) (PEDOT:PSS), polypyrrole (PPy) and copper phthalocyanine (CuPc). These FCPCs were deposited by the drop-casting technique on flexible substrates such as polyethylene terephthalate (PET), Xuan paper and ethylene–vinyl acetate (EVA) foam sheets. Wearable photoactive electrocardiogram (ECG) electrodes and flexible strain sensors were fabricated. Morphological characterization by SEM revealed a stark contrast between the smooth, continuous PEDOT:PSS films and the rough, globular PPy films. EDS confirmed the successful and homogeneous incorporation of the CuPc, evidenced by the strong spatial correlation of the nitrogen and copper signals. The highest mechanical resistance was present in the FCPCs on PET with a limit of proportionality between 4074–6240 KPa. Optical parameters were obtained by Ultraviolet–Visible Spectroscopy and their Reflectance is below 15% and could be used as photoelectrodes. Three Signal Quality Indexes (SQIs) were used to evaluate the ECG signal obtained with the electrodes. The results of all the SQIs demonstrated that the obtained signals have a comparable quality to that of a signal obtained from commercial electrodes. To evaluate the flexible strain sensors, the change in output voltage caused by mechanical deformation was measured. Full article

Practical applications such as solar power energy systems, electronic cooling, and the convective drying of vented enclosures require continuous developments to enhance fluid and heat flow. Numerous studies have investigated the enhancement of heat transfer in L-formed vented cavities by inserting heat-generating components, filling the cavity with nanofluids, providing an inner rotating cylinder and a phase-change packed system, etc. Contemporary work has examined the thermal performance of L-shaped porous vented enclosures, which can be augmented by using metal foam, using nanofluids as a saturated fluid, and increasing the wall surface area by corrugating the cavity’s heating wall. These features are not discussed in published articles, and their exploration can be considered a novelty point in this work. In this study, a vented cavity was occupied by a copper metal foam with $PPI=10$ and saturated with a copper–water nanofluid. The cavity walls were well insulated except for the left wall, which was kept at a hot isothermal temperature and was either non-corrugated or corrugated with rectangular waves. The Darcy–Brinkman–Forchheimer model and local thermal non-equilibrium models were adopted in momentum and energy-governing equations and solved numerically by utilizing commercial software. The influences of various effective parameters, including the Reynolds number ($20\le Re\le 1000$), the nanoparticle volume fraction ($0\%\le \phi \le 20\%$), the inflow and outflow vent aspect ratios ($0.1\le D/H\le 0.4$), the rectangular wave corrugation number ($N=5$ and $N=10$), and the corrugation dimension ratio ($CR=1$ and $CR=0.5$) were determined. The results indicate that the flow field and heat transfer were affected mainly by variations in $Re$, $D/H$, and $\phi$ for a non-corrugated left wall; they were additionally influenced by $N$ and $CR$ when the wall was corrugated. The fluid- and solid-phase temperatures of the metal foam increased with an increase in $Re$ and $D/H$. The fluid-phase Nusselt number near the hot left sidewall increased with an increase in $\phi$ by $\left(25–60\right)\%$, while the solid-phase Nusselt number decreased by $\left(10–30\right)\%$, and these numbers rose by around $3.5$ times when the Reynolds number increased from $20$ to $1000$. For the corrugated hot wall, the Nusselt numbers of the two metal foam phases increased with an increase in $Re$ and decreased with an increase in $D/H$, $CR$, or $N$ by $10\%$, $19\%$, and $37\%$. The original aspect of this study is its use of a thermal, non-equilibrium, nanofluid-saturated metal foam in a corrugated L-shaped vented cavity. We aimed to investigate the thermal performance of this system in order to reinforce the viability of applying this material in thermal engineering systems. Full article

Printed circuit heat exchangers (PCHE) are ideal for use in very demanding operating conditions. In addition, they are characterized by very high efficiency, which can still be increased. This paper presents new concepts for improving PCHE heat exchangers. The aim of the described work was to evaluate the potential for improving the performance of printed circuit heat exchangers by incorporating open-cell metal foam as the heat exchanger packing material. The evaluation was conducted based on the results of numerical simulation of supercritical carbon dioxide cooling flowing through printed circuit heat exchanger channels filled with 40 PPI copper foam with 90% porosity. A unit periodic region of the heat exchanger comprising two adjacent straight channels for cold and hot fluid was analyzed. The channels had a semicircular cross-section and a length of 200 mm. Studies were conducted for three different channel diameters—2, 3, and 4 mm. The range of mass flux variations for cold fluid (water) and hot fluid (sCO₂) were 300–1500 kg/(m²·s) and 200–800 kg/(m²·s), respectively. It was found that in channels filled with metal foam, carbon dioxide cooling is characterized by a higher heat transfer coefficient than in channels without metal foam. In channels of the same diameter, heat flux was 33–63% higher in favor of the channel with metal foam. Thermal effectiveness of the heat exchanger with metal foam can be up to 20% higher than in the case of a heat exchanger without foam. Despite very high pressure drop through channels filled with metal foam, thermal–hydraulic performance can also be higher—even 4.7 in the case of a 2 mm channel. However, both these parameters depend on flow conditions and channel diameter, and under certain conditions may be lower than in a heat exchanger without metal foam. The results of the presented work indicate a new direction for the development of PCHE heat exchangers and confirm that the use of metal foams in the construction of PCHE heat exchangers can contribute to increasing the efficiency and effectiveness of the processes in which they are used. Full article

Foam stability plays a critical role in a wide range of industrial and scientific applications. In this study, an innovative method is presented for assessing foam stability through electrical conductivity measurements of liquid films formed within a controlled experimental setup. A modified horizontal glass capillary system with vertically aligned copper electrodes was developed, allowing the continuous monitoring of film drainage and rupture behavior under precise humidity (92% RH) and temperature (30 °C). Experiments were conducted using various concentrations of sodium dodecyl sulfate and Ethylan 1005, with and without NaCl addition. The results demonstrate that film stability increases with higher surfactant concentrations up to a point, beyond which the addition of salt can have either stabilizing or destabilizing effects depending on whether concentration levels are below or above the Critical Micelle Concentration (CMC). At sub-CMC levels, NaCl enhanced film stability by promoting surfactant adsorption and reducing electrostatic repulsion. Conversely, in super-CMC conditions, NaCl led to film destabilization, likely due to changes in interfacial structure and micellar behavior. This approach provides a simple, sensitive, and reproducible technique to quantitatively characterize foam film stability, offering key mechanistic insights and practical guidance for the formulation and optimization of foaming systems across diverse applications. Full article

The increasing demand for critical raw materials such as copper and cobalt highlights the need for efficient beneficiation of low-grade ores. This study investigates a copper–cobalt sulfide ore (0.99% Cu, 0.028% Co) using froth flotation to produce high-grade concentrates. Various types of surfactants are applied in different ways, each serving an essential function such as acting as collectors, frothers, froth stabilizers, depressants, activators, pH modifiers, and more. A series of flotation tests employing different collectors (SIPX, PBX, AERO, DF 507B) and process conditions was conducted to optimize recovery and selectivity. Methyl isobutyl carbinol (MIBC) was consistently used as the foaming agent, and 700 g/L was used as the slurry density at 25 °C. Dosages of 30 and 100 g/t¹ were used in all tests. Notably, adjusting the pH to ~4 using HCl significantly improved cobalt concentrate separation. The optimized flotation conditions yielded concentrates with over 15% Cu and metal recoveries exceeding 80%. Mineralogical characterization confirmed the selective enrichment of target metals in the concentrate. The results demonstrate the potential of this beneficiation approach to contribute to the European Union’s supply of critical raw materials. Full article

The efficient electrochemical reduction of carbon dioxide to formate under mild conditions is a promising approach to mitigate the energy crisis, but requires the use of high-performance catalysts. The selectivity and activity of catalysts can be enhanced through multi-metal doping, further advancing the electrochemical reduction of CO₂ to formate. This study demonstrates a co-electrodeposition strategy for synthesizing SnBi electrocatalysts on pretreated copper foam substrates, systematically evaluating how the Sn²⁺/Bi³⁺ molar ratio in the electrodeposition solution and the applied current density affect the catalytic performance for CO₂-to-formate conversion. Optimal performance was achieved with a molar ratio of Sn²⁺ to Bi³⁺ of 1:0.5 and a deposition current density of 3 mA cm⁻², resulting in a formate Faradaic efficiency (FE_formate) of 97.80% at −1.12 V (vs. RHE) and a formate current density of 26.9 mA·cm⁻². Furthermore, the Sn₁Bi_0.50-3 mA·cm⁻² electrode demonstrated stable operation at the specified potential for 9 h, maintaining a FE_formate above 90%. Compared to previously reported metal catalysts, the SnBi catalytic electrode exhibits superior performance for the electrochemical reduction of CO₂ to HCOOH. The study highlights the significant impact of the metal ion molar ratio and deposition current density in the electrodeposition process on the characteristics and catalytic performance of the electrode. Full article