Search Results (41)

This study investigates the integration of phase change materials (PCMs) and recycled textile fibers into cementitious composites to improve the thermomechanical performance and energy efficiency of building envelopes. Experimentally, eco-efficient mortars were developed by partially replacing sand with recycled textile fibers (0–40% by volume) and microencapsulated PCM (0–30% by volume) across sixteen distinct formulations. The fresh-state workability, apparent density, compressive strength, and flexural strength were systematically characterized after 28 days of curing. Results show that while PCM addition lowers composite density and mechanical resistance, textile fibers effectively mitigate compressive strength loss and enhance flexural strength by up to 70% through crack-bridging mechanisms. Numerically, an open-source conjugate heat transfer (CHT) framework was developed in OpenFOAM using the chtMultiRegionFoam solver and a temperature-dependent apparent heat capacity formulation to simulate the thermal response of concrete walls lined with an inner textile-reinforced mortar (TRM) skin. The numerical framework was experimentally validated against the literature’s benchmark data, reproducing diurnal surface temperature profiles with high fidelity. A parametric investigation of the inner composite skin thickness (2, 4, and 6 mm in the numerical model, corresponding to 20, 40, and 60 mm prototype layers) was conducted. The analysis reveals that incorporating a PCM-loaded TRM skin dampens internal thermal swings, lowers the required cooling demand, and reduces occupant thermal stress by over 20% compared to plain concrete. This integrated approach establishes an eco-efficient route for valorizing industrial textile waste while embedding passive thermal regulation directly within structural envelopes. Full article

A computational fluid dynamics and conjugate heat transfer (CFD+CHT) methodology is developed for the thermal simulation of a commercial prismatic ${\mathrm{LiFePO}}_4$ cell under charging and discharging operating conditions. The approach couples a three-dimensional representation of the battery, including a simplified description of its internal layered structure, with an electrochemical–thermal heat-generation model implemented as a temperature- and time-dependent volumetric source term. The heat source is applied within the active layers of the cell and updated during the transient simulation according to the local thermal state and to the evolution of the state of charge. The methodology is applied to 1C and 2C cycles under natural convection and forced-air cooling at free-stream velocities of $10\mathrm{m}{\mathrm{s}}^{-1}$ and $20\mathrm{m}{\mathrm{s}}^{-1}$. A dedicated wind-tunnel campaign is carried out on the same cell, instrumented with type-K thermocouples distributed over its external surfaces, to provide experimental data for model validation. The results show that the proposed framework accurately reproduces the main wall-temperature trends observed experimentally. Under natural convection, the temperature distribution remains nearly uniform, whereas forced convection produces more pronounced vertical and in-plane gradients. For the charge cycles, the comparison between CFD predictions and end-of-cycle measurements yields a mean absolute error (MAE) of ${0.66}^{\circ }\mathrm{C}$ and a root-mean-square error (RMSE) of ${0.82}^{\circ }\mathrm{C}$ over 168 measurement locations. The discharge cycles yield a comparable level of agreement (MAE ${0.65}^{\circ }\mathrm{C}$, RMSE ${0.81}^{\circ }\mathrm{C}$ over 168 probe points), confirming the predictive capability of the methodology for both operating modes. Full article

Spray impingement cooling is a well-established heat removal technique employed across a wide range of industrial processes. A particularly significant cooling regime arises when the temperature of the cooled surface surpasses the Leidenfrost temperature of the spray. Developing an accurate numerical framework for this regime holds considerable potential for optimising industrial applications such as cryogenic machining and spray quenching. This paper presents a Eulerian–Lagrangian Conjugate Heat Transfer (CHT) model tailored for spray impingement under Leidenfrost conditions. Two heat transfer sub-models are incorporated to characterise droplet–solid thermal interaction: the first, developed by Breitenbach, is grounded in a theoretical analysis of the droplet impingement process, while the second, proposed by Deb, relies on a semi-empirical correlation. Both models were validated against an experimental correlation obtained from a literature study on orthogonal water spray impingement, yielding mean relative errors of 3.54% for the Deb model and 5.2% for the Breitenbach model across a broad range of operating conditions and surface temperatures. Full article

In this work, a partitioned coupling algorithm is developed by integrating the improved discrete velocity method (IDVM) with the lattice Boltzmann flux solver (LBFS) to address conjugate heat transfer (CHT) in microscale systems across all flow regimes. Specifically, the flow field is solved by the IDVM, generating a heat flux that acts as a Neumann boundary condition at the interface for the solid domain. Subsequently, the LBFS calculates the thermal distribution inside the solid, and the updated temperature at the interface is then applied to the fluid computations as a Dirichlet condition. The proposed framework effectively combines the strengths of the IDVM in modeling rarefied gas flows with the advantages of the LBFS in handling heat conduction in complex geometries. Crucially, the current approach implicitly captures temperature jump discontinuities at the conjugate boundary, bypassing the requirement for supplementary jump conditions. To evaluate its performance, several CHT test cases involving rarefied gas in microchannels were conducted. Computational evidence suggests that the scheme is robust across diverse flow regimes. Full article

One of the most important goals in developing centrifugal pumps for liquid hydrogen transport is to minimize the temperature rise of the working fluid caused by internal and external heat sources during operation. In this paper, as part of our evaluation of the internal insulation characteristics of a centrifugal pump for liquid hydrogen transport, we removed the external vacuum insulation layer and installed a Teflon insulation layer inside the pump. We investigated the process of heat transfer from the outside to the working fluid due to internal heat flow loss during the pumping process and the resulting temperature rise of the working fluid through CHT (Conjugate Heat Transfer) analysis. The results show that, compared to a pump without a Teflon insulation layer, increasing the insulation layer thickness to 10 mm reduces external heat input from about 1300 W to 300 W. Furthermore, the Teflon insulation layer reduces the heat generated by internal heat flow losses during pump operation from approximately 37 W to 11 W. Full article

Based on a realistic three-dimensional geometric model, this study numerically investigates the influence of yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBCs) on the aerothermal performance of an annular combustor by employing a conjugate heat transfer (CHT) and non-premixed reactive flow coupling approach. Considering the inner and outer liners, double-wall exhaust bends, and the full configuration of cooling holes, two cases—with and without the TBCs—were analyzed. The results reveal that the application of TBCs markedly modifies the near-wall flow structures and heat transfer characteristics. The cooling air mass flow rate decreases from 0.1211 kg/s to 0.1023 kg/s, corresponding to a 15.5% reduction in cooling load. The main recirculation zone becomes more compact, with enhanced vortex intensity, smoother velocity distribution, and improved flame stability. The high-temperature core region extends further downstream, and the peak temperature increases by approximately 80–100 K, indicating more complete combustion and greater heat retention. The outlet temperature distribution factor (OTDF) decreases from 57.34% to 44.48%, leading to a 22.4% improvement in temperature uniformity. The average wall temperatures of the inner liner, outer liner, and exhaust bend decrease by 3.7%, 8.8%, and 7.5%, respectively, with local peak reductions exceeding 250 K. The study demonstrates that the YSZ TBCs enhances the combustor’s thermal protection capability, flow stability, and temperature uniformity through a coupled mechanism of “thermal insulation–flow reconstruction–energy redistribution.” It should be noted that this study considers only the effect of the ceramic top coat of the TBCs, excluding the metallic bond coat and the thermally grown oxide (TGO) layer. Full article

Accurate conjugate heat transfer (CHT) analysis is critical to the thermal management of hypersonic vehicles operating in rarefied environments, where non-equilibrium gas dynamics dominate. While numerous sophisticated CHT solvers exist for continuum flows, they are physically invalidated by rarefaction effects. This paper presents a novel partitioned coupling framework that bridges this methodological gap by utilizing the preCICE library to non-intrusively integrate the Direct Simulation Monte Carlo (DSMC) method, implemented in SPARTA, with the finite element method (FEM) via FEniCS for high-fidelity simulations of rarefied hypersonic CHT. The robustness and accuracy of this approach are validated through three test cases: a quasi-1D flat plate benchmark confirms the fundamental coupling mechanism against a reference finite difference solution; a 2D flat-nosed cylinder demonstrates the capability of the framework to handle highly non-uniform heat flux distributions and resolve the ensuing transient thermal response within the solid; finally, a standard cylinder case confirms the compatibility with curved geometries and its stability and accuracy in long-duration simulations. This work establishes a validated and accessible pathway for high-fidelity aerothermal analysis in rarefied gas dynamics, effectively decoupling the complexities of multi-physics implementation from the focus on fundamental physics. Full article

Predicting phase-change heat transfer in two-phase closed thermosyphons (TPCTs) represents a significant challenge owing to the complex interaction of boiling, condensation, and conjugate heat transfer (CHT) mechanisms. This study presents a numerical investigation of a TPCT using the Combined Boiling Model (CBM) within a conjugate heat transfer (CHT) framework. Unlike prior TPCT studies, the CBM integrates an improved RPI-based wall boiling model with sliding bubble dynamics, a laminar film condensation closure, and Lee-type bulk phase change in a single, energy-consistent formulation suited for engineering-scale meshes and time-steps. Building on these extensions, we demonstrate the approach on a vertical TPCT with full CHT and validate it against experiments and a VOF–Lee reference. Simulations for heat loads ranging from 173 to 376 W capture key flow features, including vapour generation, vapour-pocket dynamics, and thin-film condensation, while reducing temperature deviations typically below 3% in the evaporator and adiabatic sections and about 2 to 5% in the condenser. The results confirm that the CBM provides a physically consistent and computationally efficient approach for predicting evaporation–condensation phenomena in TPCTs. Full article

Rotating detonation engines (RDEs) are expected to have higher specific work and efficiency, but the high-temperature transonic flow delivered by the combustor poses relevant design and technological difficulties. This work proposes a 1D model for turbine internal cooling design which can be used to explore multiple design options during the preliminary design of the cooling system. Being based on an energy balance applied to an infinitesimal control volume, the model is general and can be adapted to other applications. The model is applied to design a cooling system for a pre-existing stator blade geometry. Both the inputs and the outputs of the 1D simulation are in good agreement with the values found in the literature. Subsequently, 1D results are compared to a full conjugate heat transfer (CHT) simulation. The agreement on the internal heat transfer coefficient is excellent and is entirely within the uncertainty of the correlation. Despite some criticality in finding agreement with the thermal power distribution, the Mach number, the total pressure drop, and the coolant temperature increase in the cooling channels are accurately predicted by the 1D code, thus confirming its value as a preliminary design tool. To guarantee the integrity of the blade at the extremities, a cooling solution with coolant injection at the leading and trailing edge is studied. A finite element analysis of the cooled blade ensures the structural feasibility of the cooling system. The computational economy of the 1D code is then exploited to perform a global sensitivity analysis using a polynomial chaos expansion (PCE) surrogate model to compute Sobol’ indices. Full article

Over the last decades, Computational Fluid Dynamics (CFD) has become a fundamental tool for the design of gas turbine combustors, partly making up for the costs and duration issues related to the experimental tests involving high-pressure reactive processes. Nevertheless, high-fidelity simulations of reactive flows remain computationally expensive, particularly for conjugate heat transfer (CHT) analyses aimed at predicting liner metal temperatures and characterising wall heat losses. This work investigates the robustness of a cost-effective numerical setup for CHT simulations, focusing on the prediction of cold-side thermal loads in industrial combustor liners under realistic operating conditions. The proposed approach is tested using both Reynolds-Averaged Navier–Stokes (RANS) and unsteady Stress-Blended Eddy Simulation (SBES) turbulence models for the combustor flame tube, coupled via a time desynchronisation strategy with transient heat conduction in the solid domain. Cold-side heat transfer is modelled using a 1D correlation-based tool, runtime coupled with the CHT simulation to account for cooling-induced thermal loads without explicitly resolving complex cooling passages. The methodology is applied to a single periodic sector of the NovaLT^TM16 annular combustor, developed by Baker Hughes and operating under high-pressure conditions with natural gas. Validation against experimental data demonstrates the methodology’s ability to predict liner metal temperatures accurately, account for modifications in cooling geometries, and support design-phase evaluations efficiently. Overall, the proposed approach offers a robust trade-off between computational cost and predictive accuracy, making it suitable for practical engineering applications. Full article

Thermal barrier coating (TBC) around film-cooling holes is a key failure location for turbine blade TBC. This study built a numerical model. The model used conjugate heat transfer (CHT) and sequential thermal-stress calculation methods. It analyzed the temperature and stress fields in the TBC around film-cooling holes. The holes had different inclination angles (30°, 45°, and 60°). It also explored the balance between cooling effectiveness and stress at these angles. Results show that increasing the film-cooling hole angle reduces the cooling film coverage area significantly. Cooling effectiveness becomes worse. The temperature field near the holes is complex. Sharp temperature gradients exist there. An inverse temperature gradient appeared in the top coat (TC) layer at the hole exit. Stress in the TBC was analyzed next. Analysis was conducted under rated operating conditions. Analysis was also completed after 500 h of creep under these conditions. Stress concentration around the holes is obvious. At room temperature, Mode I cracks easily form upstream of the holes. Mode II cracks easily form downstream. Under rated conditions, mixed-mode cracks (I + II) easily form downstream. The coating experiences larger stress at room temperature. This means that the coating is more likely to spall during cooling. Increasing the hole angle can reduce stress concentration. It can also lower the chance of crack formation. However, a larger angle increases the normal momentum of the cooling jet. This reduces film coverage. Therefore, after considering both cooling effectiveness and TBC failure, the 45° film-cooling hole is optimal. Full article

In the automotive industry, the increasing stringent standards to reduce fuel consumption and pollutant emissions has driven significant advancements in turbocharging systems. The centrifugal compressor, as the most widely used power-absorbing machinery, plays a crucial role but remains one of the most complex components to study and design. While most numerical studies rely on adiabatic models, this work analyses several Computational Fluid Dynamics (CFD) models with conjugate heat transfer (CHT) of varying complexity, incorporating real solid components. This approach allowed a sensitivity analysis of the performance obtained from the different models compared to the adiabatic case, highlighting the effects of internal heat exchange losses. Moreover, an analysis of the temperature distribution of the wheel was conducted, along with a thermal assessment of the various heat flux contributions across the different components, to gain a deeper understanding of the performance differences. The impact of including the seal plate has been evaluated and different boundary conditions on the seal plate have been tested to assess the uncertainty in the results. Finally, the influence of heat exchange between the shroud and the external environment is also examined to further refine the model’s accuracy. One of the objectives of this work is to obtain a correct temperature profile of the rotor for a subsequent thermo-mechanical analysis. Full article

Icing poses a serious threat to flight safety, and ice accretion simulations are essential for addressing aircraft icing problems. In ice accretion prediction, systematic research covering all icing conditions based on actual flight phases is lacking, and the performance of anti-icing systems has not been investigated. In this study, maximum ice thickness prediction models for airfoils considering all flight phases were developed, and the performance of hot air anti-icing systems was analyzed. A hot air anti-icing system model was established, and the anti-icing effectiveness of the system under severe icing conditions was evaluated via conjugate heat transfer (CHT) calculations. The calculation results showed that during climbing above 10,000 ft under glaze ice conditions, the maximum ice thickness reached 13.47 mm at −6 °C, with a median volumetric diameter (MVD) of 20 μm. Under rime ice conditions, the maximum thickness exhibited linear relationships with the icing parameters, remaining below 5 mm. The calculation results revealed nonlinear relationships between maximum ice thickness on the airfoil leading edge and the icing conditions. Ice thickness models were established via polynomial regression. The maximum ice thickness data were classified, and 15 regression models were obtained. The relative errors between the predicted and calculated values remained below 3%, demonstrating high predictive accuracy. These models were employed to estimate the effectiveness of piccolo tube hot air anti-icing systems under the most severe icing conditions. The results indicated that 100% anti-icing efficiency was achieved at high ambient temperatures (above −10 °C). During takeoff, holding, and climbing phases with a high speed of 154.3 m/s, the system may face challenges in maintaining anti-icing protection, resulting in runback ice with a maximum thickness exceeding 5 mm. Full article

The impetus of the present work is to propose a comprehensive methodology for the numerical evaluation of drying/curing, as one of the most complex and energy-consuming stages in the paint shop plant, to guarantee a decrease in energy costs without sacrificing the final paint film quality and manufacturability. Addressing the complexities of vehicle assembly, such as intricate geometry and multi-zoned ovens, our approach employs a sophisticated conjugate heat transfer (CHT) algorithm, developed under the OpenFOAM framework, providing efficient heat transfer with the accompaniment of the Large Eddy Simulation (LES) turbulence model, thereby delivering high-fidelity data. This algorithm accurately simulates turbulence and stress in the oven, validated through heat sink cases and closely aligning with experimental data. Applying modifications for the intake supply heated airflow rate and direction leads to optimal recirculation growth in the measured mean temperature within with the curing oven and along the car body surface, saving a significant amount of energy. Key adjustments in airflow direction improved temperature regulation and energy efficiency while enhancing fluid dynamics, such as velocity and temperature distribution. Furthermore, the study integrates machine learning to refine the oven’s heat-up region, which is crucial for preventing paint burnout. A data-based model using a variational auto-encoder (VAE) and an artificial neural network (ANN) effectively encodes temperature and velocity fields. This model achieves an impressive 98% accuracy within a 90% confidence interval, providing a reliable tool for predicting various operational conditions and ensuring optimal oven performance. Full article

This article focuses on the analysis of a direct air-cooled rotor winding of a wound field synchronous machine, the innovation of which lies in the increase in the internal cooling surface, the cooling of the winding compared to the conventional inter-pole cooling, and the development of a CHT evaluation model accordingly. Conjugate heat transfer (CHT) analysis is used to explore the cooling efficacy of a parallel-cooled hollow-conductor winding of a salient-pole rotor and to identify a cooling performance map. The use of high current densities of 15–20 Arms/mm² in directly cooled windings requires high cooling intensity, which in the case of air cooling results not only in flow velocities above 15 m/s to ensure permissible operating temperatures, but also the need for coolant distribution and heat transfer studies. The experiments and calculations are based on a non-rotating machine and a wind tunnel using the same rotor coil(s). CHT-based thermal calculations provide not only reliable results compared to experimental work and lumped parameter thermal circuits with adjusted aggregate parameters, but also insight related to pressure and cooling flow distribution, thermal loads, and cooling integration issues that are necessary for the development of high power density and reliable electrical machines. The results of the air-cooling integration show that the desired high current density is achievable at the expense of high cooling intensity, where the air velocity ranges from 15 to 30 m/s and 30 to 55 m/s, distinguishing the air velocity of the hollow conductor and bypass channel, compared to the same coil in an electric machine and a wind tunnel at the similar thermal load and limit. Since the hot spot location depends on cooling integration and cooling intensity, modeling and estimating the cooling flow is essential in the development of wound-field synchronous machines. Full article