Search Results (235)

Meso-scale combustors experience major challenges associated with flame instability, excessive wall heat losses, and limited reactant residence time due to their high surface-to-volume ratios. This study numerically investigates the thermo-fluid behaviour of hydrogen-fuelled vortex flames in a frustum meso-scale combustor under stoichiometric conditions (φ = 1.0). Three outlet-diameter configurations of 6 mm, 8 mm, and 10 mm were analysed under stoichiometric hydrogen–air conditions at air mass flow rates of 40, 80, and 120 mg/s, corresponding to Reynolds numbers of approximately 624–1780, with Computational Fluid Dynamics (CFD) used to evaluate the influence of combustor geometry on thermal confinement, wall temperature distribution, and flame stabilisation characteristics. The numerical simulations were performed in ANSYS Fluent 14.0 using the RNG k–ε turbulence model coupled with the Eddy Dissipation combustion model. The results indicate that reducing outlet diameter significantly enhances thermal confinement and recirculation behaviour within the combustor core. The temperature contours showed a maximum flame temperature of approximately 2.23 × 10³ K, while the 6 mm outlet configuration produced a more compact and axially elongated high-temperature core compared with the 10 mm configuration. The 6 mm outlet enhanced thermal localisation by approximately 10.4% and increased residence time by 66.8% relative to the 10 mm outlet. The peak inner wall temperature ranged from approximately 752 K to 1085 K depending on outlet diameter and mass flow rate. The 6 mm outlet exhibited the highest average wall temperature of approximately 909 K, followed by the 8 mm outlet (879 K) and the 10 mm outlet (838 K). Compared with the 10 mm outlet, the 6 mm configuration increased the average wall temperature by approximately 8.5%, indicating improved thermal confinement and heat retention within the combustor. These results indicate that outlet diameter strongly influences the balance between thermal confinement, flame stabilisation, and flow resistance. Full article

High-power-density insulated gate bipolar transistor (IGBT) modules in new energy vehicles require efficient heat dissipation and good temperature uniformity. This study proposes a tri-objective topology optimization method for a liquid-cooled heat sink using average temperature, temperature variance, and flow dissipation as the objective functions. A two-dimensional model was established in COMSOL to investigate the effects of the fluid volume fraction, inlet pressure, and optimization-weight distribution on the optimized topology and thermo-hydraulic performance. The results show that a fluid volume fraction of 0.4 and an inlet pressure of 15 Pa provide the best overall performance. Compared with the bi-objective design, introducing temperature variance as a third objective reduces temperature variance by 50.23%, with only a 1.08% increase in average temperature. Three-dimensional simulations further verify the optimized design. Compared with a conventional pin-fin heat sink, the topology-optimized structure reduces the average temperature by 10.43% and the temperature variance by 44.37%, while increasing the flow dissipation by 49.57%. These results show that tri-objective topology optimization is an effective method for improving the thermal management of high-power-density IGBT modules. Full article

The rapid growth in the electric vehicle sector has increased demand for advanced battery thermal management systems (BTMSs) with high heat-dissipation capacity and temperature uniformity. Immersion cooling using dielectric fluids has recently been recognized as a promising alternative technology to conventional indirect liquid cooling methods. This study investigates the thermal and hydrodynamic behaviour of a sixteen-lithium-ion cell battery (LIB) module immersed in low-viscosity dielectric fluids using three-dimensional computational fluid dynamics simulations. In this context, a total of twenty dielectric fluids are evaluated using the ANSYS Fluent solver, with particular emphasis on the effects of key thermophysical properties, including viscosity, density, specific heat capacity, and thermal conductivity. The simulation findings reveal that mineral oil and PAO4 yield the lowest maximum LIB cell temperatures, with a reduction of approximately 4 K compared to the least effective dielectric fluids, such as undecane and cumene. Moreover, in terms of temperature uniformity, mineral oil, Novec 7000, and PAO4 exhibit the most homogeneous temperature distributions among the twenty dielectric fluids. In addition, they show an improvement in the temperature uniformity index of approximately 32.4% compared with the least effective dielectric fluid, cumene. On the other hand, mineral oil and PAO4 generate significantly higher pressure drops because of their relatively high viscosities, which increases hydraulic resistance and pumping power requirements. These findings demonstrate that excellent thermal performance does not necessarily correspond to optimal overall thermo-hydraulic behaviour. Overall, the results confirm that immersion-BTMS performance is governed by a complex interaction between dielectric fluid thermophysical properties and flow behaviour, highlighting the importance of coupled thermo-hydraulic optimization in the selection of dielectric fluids for next-generation immersion-cooled battery systems. Full article

Cells operate as open thermodynamic systems where energy transformations and transport processes occur across membranes, exhibiting distinct thermo-electro-biochemical behaviours in healthy versus diseased states. Living organisms generate waste heat due to internal irreversibility, which dissipates into the environment and serves as an observable flow of information. By analysing this heat loss and its changes under external influences, new insights into cellular behaviour can be gained. This paper highlights recent advances in this thermodynamic approach, which frames living systems as black boxes, focusing on their input–output dynamics and introducing the emerging field of bioengineering thermodynamics. A key challenge in applying extremely low-frequency electromagnetic fields (ELF-EMF) to proliferative disorders has been the empirical selection of effective field parameters. To address this, we employed a bio-thermodynamic engineering model to calculate the ELF frequency that maximizes mean entropy changes based on cellular biophysical parameters. This entropy change corresponds to a metabolic shift that reduces cell proliferation. Experimental validation was performed on six human cancer cell lines, where proliferation rates served as indicators confirming the model’s predictions. For the first time, this approach enabled the calculation and experimental validation of ELF frequencies selectively effective on different cell types, demonstrating a promising method for targeted therapeutic applications. Full article

This study proposes two enhanced configurations for a parallel-channel cold plate in battery thermal management systems to improve thermo-hydraulic performance through the introduction of cylindrical and fin-type baffles. A three-dimensional computational fluid dynamics (CFD) model was developed in ANSYS to simulate fluid flow and heat transfer within the cold plate. A Poly-Hexcore meshing strategy with local refinement and near-wall inflation layers was employed to ensure numerical accuracy while maintaining computational efficiency. A parametric investigation involving 150 cases was conducted to identify the optimal channel configuration. The results indicate that, among the investigated configurations and under the present numerical operating conditions, the fin-type baffle exhibits the most balanced thermo-hydraulic behavior by achieving an effective balance between heat-transfer enhancement and pressure-drop penalty. The present study provides a CFD-based framework for the design and optimization of parallel-channel cold plates for battery thermal management applications. Full article

This study presents a controlled three-dimensional conjugate CFD comparison of counter-flow and parallel-flow concentric tube heat exchangers under identical Reynolds number conditions (Re = 1000–2000). By isolating the flow configuration as the only varying parameter, the intrinsic influence of flow arrangement on thermo-hydraulic performance is systematically evaluated. Unlike enhancement-focused studies involving geometric modification or advanced working fluids, the present study focuses exclusively on the influence of flow arrangement under identical operating conditions. The analysis focuses on heat transfer rate, outlet temperature distribution, pressure drop, thermo-hydraulic performance index, and a normalized heat transfer ratio (Ψ). The results show that the counter-flow configuration consistently enhances heat transfer by 3.17–4.29% compared to parallel-flow operation, while maintaining nearly identical pressure-drop values. This improvement is attributed to the preservation of a higher logarithmic mean temperature difference (LMTD) along the exchanger length, sustaining the thermal driving force under laminar flow conditions. In contrast, the parallel-flow configuration exhibits a rapid decay in temperature difference near the inlet region, limiting effective heat transfer. Although heat transfer increases with Reynolds number in both configurations, the thermo-hydraulic performance index decreases due to the relatively higher increase in hydraulic resistance. Comparison with classical laminar flow behavior confirmed the physical consistency and reliability of the numerical model. The findings demonstrate that counter-flow arrangement provides a measurable thermal advantage without additional hydraulic penalty. The study offers a physically consistent and practically relevant framework for the design and optimization of concentric tube heat exchangers used in engine cooling and waste heat recovery applications. Full article

The reliable joining of ultra-thick aluminum alloy plates remains a critical technical challenge in modern industrial manufacturing, often hindered by defects such as porosity and excessive distortion associated with conventional fusion welding. The novelty of this work lies in the characterization of the intermediate layer overlapping zone in 110 mm ultra-thick plates, which has rarely been reported. The motivation is to overcome the limitations of single-pass FSW for thick plates, such as insufficient material flow and high tool forces, by adopting a sequential double-sided strategy. Furthermore, this technique may help moderate the through-thickness heat input variation, although no direct thermal measurements were made. The weld nugget zone consists of uniformly fine, recrystallized α-Al grains. In contrast, the heat-affected zone displays distinctly laminar grain structures. The overlapping regions within the intermediate layer, which undergo two thermal cycles, exhibit refined grain sizes. A well-defined interface is evident between the advancing-side weld nugget zone and the thermo-mechanically affected zone. The overall tensile strength of the FSW joint is approximately 81% of the base material, and the tensile specimen fractured at the interface between the thermo-mechanically affected zone and the heat-affected zone. Along the thickness of the weld joint, a “W”-shaped microhardness distribution is observed at the surface and subsurface, whereas the intermediate layer exhibits a distinct “V”-shaped profile. The lowest microhardness value is located in the intermediate layer overlapping area due to the insufficient heat input and limited grain growth in this region. In summary, under the specific welding parameters tested (130 rpm, 15 mm/min, 110 mm thick), double-sided friction stir welding produces defect-free joints in AA 5052-H32, suggesting its potential for thick-plate applications, offering a practical and effective solution for manufacturing high-performance aluminum alloy structures. Potential industrial applications include pressure vessels for chemical storage, ship hull structures, and heavy-duty transportation components where ultra-thick aluminum plates are required. Full article

Deep geological disposal is widely recognized as the most reliable strategy for the long-term isolation of high-level radioactive waste (HLW). In granitic host rocks, fractures in the near-field represent the primary pathways for groundwater flow and potential radionuclide migration. The self-sealing capacity of carbonate-filled fractures, along with its long-term effectiveness, plays a critical role in maintaining the integrity of the multi-barrier system and ensuring repository safety. Near-field fractures undergo complex thermo–hydro–mechanical–chemical (THMC) coupled evolution driven by excavation-induced disturbances, decay heat, groundwater saturation, and ongoing water–rock interactions. Within the confined fracture spaces, carbonate minerals may persistently undergo precipitation–dissolution cycling and micro- to nanoscale structural reorganization, resulting in progressive reductions in fracture connectivity and hydraulic transmissivity. However, existing studies have largely focused on short-term sealing effects, with limited systematic understanding of the long-term safety functions. In this context, this study comprehensively investigates carbonate-induced self-sealing in granitic fractures within the near-field of a repository under realistic THMC-coupled conditions. We elucidate the micro- and nanoscale heterogeneous precipitation characteristics governed by non-classical nucleation pathways, reveal how dynamic precipitation–dissolution equilibria facilitate ongoing reductions in fracture transmissivity, and propose a multi-dimensional framework for long-term hydraulic, mechanical, and chemical performance assessment. Our findings demonstrate that carbonate self-sealing operates as a dynamic, reorganizing, and multi-mineral cooperative mechanism rather than a static, one-directional process. Its core safety function lies in the sustained suppression of fracture transmissivity. The mechanistic insights and evaluation framework proposed in this study provide a foundation for integrating natural carbonate self-sealing with engineered barrier system design, thereby improving fracture control, advancing long-term safety assessment, and optimizing the design of HLW deep geological repositories. Full article

Introduction: Efficient geothermal energy extraction has the potential to significantly alleviate the shortage of fossil energy, but low extraction efficiency and an insufficiently understood extraction mechanism remain key bottlenecks hindering its large-scale deployment. Method: This study develops a fluid–solid coupled numerical model based on the intrinsic physical properties of geological reservoirs to systematically analyze the energy extraction characteristics of geothermal systems. Simultaneously, the effects of key geological factors on fluid flow behavior within geothermal reservoirs are investigated. Furthermore, molecular dynamics simulations are employed to elucidate the microscopic mechanisms by which driving fluids facilitate geothermal energy extraction. Results: The results demonstrate that the thermo-hydraulic–mechanical (THM) numerical model was validated through a comparison with benchmark data reported in previous studies, exhibiting a high degree of agreement with geothermal extraction performance. The model further confirms that heat transport in the geothermal reservoir is characterized by a pronounced “tongue-in” isotherm pattern during the extraction process. Discussion: Lower initial temperatures of the driving fluid lead to more rapid geothermal energy extraction compared with higher initial temperatures, and the “tongue-in” phenomenon becomes increasingly pronounced as the initial injection temperature decreases. Moreover, increased injection pressure significantly enhances geothermal energy extraction efficiency; however, reduced pressure differentials markedly suppress the development of the “tongue-in” pattern and decrease reservoir permeability. In addition, water used as a heat-driving fluid achieves higher thermal extraction efficiency than water, while simultaneously exerting a stronger moderating effect on the permeability evolution of geothermal reservoirs. Conclusions: The simulation results obtained from the thermo-hydraulic-mechanical (THM) numerical model provide fundamental data to support the efficient development of geothermal reservoirs, while the associated analyses offer valuable insights into the selection of appropriate driving fluids for reservoirs with distinct geological characteristics. Full article

Heat-assisted metal spinning comprises incremental forming routes, conventional spinning, shear spinning and flow forming, performed at elevated temperature to increase formability. This review consolidates the main advances of the last fifteen years. It outlines spinning mechanics and the rationale for heating (higher ductility, lower forming forces and microstructure control), then compares global and local heating strategies (furnace, flame, induction, laser and hot-gas convection) in terms of temperature uniformity, industrial practicality, energy efficiency and cost. Key process parameters (spindle speed, feed rate and thickness reduction) are discussed with respect to defect formation, and representative windows for defect mitigation are reported. Progress in modeling is reviewed, including coupled thermo-mechanical finite element simulations, damage/formability prediction and emerging data-driven optimization. The review also summarizes microstructural evolution under heat-assisted conditions, phase transformation, dynamic recrystallisation and grain growth, and its impact on final properties. Across more than 100 studies, evidence shows that robust thermal management can roughly double achievable deformation before failure and enables property tailoring in difficult-to-form alloys (Ni-based alloys, high-strength steels, Al, Mg and Ti). Remaining challenges include reliable in situ temperature measurement/control and improved predictive fidelity of simulations. Future opportunities include digital twins, real-time sensing and adaptive, machine-learning-assisted control. Full article

This paper presents the development and implementation of a two-degree-of-freedom, model-based controller designed to enhance the efficiency and flexibility of a certain class of circuits used in thermo-hydraulic applications. The controller addresses significant challenges such as time-variable transport delays and actuator coupling, which are common in dynamic testing environments. By utilising a model-based control approach and the Smith predictor configuration, the proposed controller simultaneously tracks supply temperature and mass flow rate with improved performance compared to the proportional–integrative–derivative (PID) controller used in our laboratory. The system’s effectiveness is demonstrated through a virtual hydraulic complex model developed in the OpenModelica environment and experimental tests, following the implementation of the controller in the laboratory real-time control software. Both the simulation and experimental results indicate that the controller can closely follow pre-programmed temperature and flow rate waveforms while effectively rejecting disturbances, with an RMSE reduction of up to about 80% under the specific test protocol used in this work, making it suitable for applications required to deal with the above constrains, such as laboratory dynamic testing and thermo-mechanical and chemical process regulation. Full article

Airfoil fin Printed Circuit Heat Exchangers (PCHEs) offer significant advantages in reducing flow resistance, promoting turbulence, and enhancing heat transfer performance due to their discrete fin configuration. However, compared with conventional continuous-channel structures, the geometric discontinuities and sharp trailing edges introduced by discrete fins tend to induce severe stress concentration at the fin roots, resulting in a more complex structural response. In this study, a PCHE core with NACA0020 airfoil fins is investigated. Finite element analysis combined with a sequential one-way thermo-structural coupling approach is conducted to characterize the fins’ stress and deformation behavior under high temperature and pressure. The plate region is evaluated based on the linear elastic stress criteria specified in ASME Boiler and Pressure Vessel Code Section III, while localized yielding regions such as the fin roots are assessed using an equivalent plastic strain indicator. Results indicate that the structural response of the PCHE core is dominated by pressure loading under the investigated operating conditions with ΔT = 18 °C and ΔP = 12.05 MPa, whereas thermal stress caused by constrained thermal expansion mainly modifies local stress distributions and has a limited effect on global deformation. Owing to the discontinuous support provided by discrete airfoil fins, the fin roots act as the primary load-transfer path and sustain higher stress levels. The maximum von Mises stress is observed at the trailing edge of the fin root on the high-pressure side, while the largest deformation occurs in the unsupported plate region and is governed by bending. Parametric analysis indicates that, within the investigated parameter range, a fully staggered fin arrangement promotes more uniform load distribution and exhibits the most favorable structural response. In contrast, increasing the fin chord length and relative thickness reduces the overall load-carrying capacity of the core. Finally, a power-law predictive correlation for the maximum total plate deformation was developed, showing that the parameter influence on plate structural response follows the order horizontal pitch (L_h) > vertical pitch (L_v) > channel etching depth (L_e) > staggered pitch (L_s). In contrast, normalized sensitivity analysis of the maximum fin-root von Mises stress shows the order staggered pitch (L_s) > horizontal pitch (L_h) > vertical pitch (L_v) > channel etching depth (L_e), indicating that global plate deformation and local fin-root response are governed by different structural mechanisms. Full article

This research presents a two-dimensional transient thermo-hydraulic model designed to study how temperature and pressure change within a wellbore during CO₂ tubing fracturing. The model integrates one-dimensional axial compressible flow with radial heat transfer across the tubing, annulus, casing, cement sheath, and surrounding geological formation. Using the predicted temperature and pressure distributions, the phase behavior of the fracturing fluid along the wellbore is assessed. To enhance the accuracy of phase predictions, a visualization experiment is performed on a CO₂-based fracturing fluid containing 5 wt% of the thickener HPG. The critical transition conditions obtained experimentally are used to adjust the model accordingly. The study systematically examines the influence of key operational parameters such as injection rate, wellhead pressure, injection temperature, and the geothermal gradient of the formation. Findings reveal that injection conditions mainly govern the temperature and velocity fields, while heat transfer from the formation has a lesser impact during short-term injections. Pressure steadily decreases along the wellbore due to friction and fluid compressibility. A method based on density gradients is introduced to determine the depth at which phase transitions occur. Overall, this work offers a practical approach for predicting thermo-hydraulic behavior and phase changes during CO₂ fracturing processes. Full article

Efficient thermal management is critical for maintaining the safety, durability, and performance of lithium-ion batteries used in electric vehicles (EVs). In this study, a comprehensive numerical investigation is conducted to evaluate the heat transfer characteristics of mono- and hybrid-nanofluids in a microchannel-cooled lithium-ion battery module. A three-dimensional computational model of a 5S7P battery module composed of cylindrical 21700 cells is developed. Battery heat generation during 3C high discharge rate operation is predicted using the Newman-Tiedemann-Gu-Kim (NTGK) electrochemical model, while coolant flow and heat transfer are simulated using the governing conservation equations for mass, momentum, and energy. The cooling system consists of six liquid-cooling plates with circular microchannels. The performance of water-glycol (50/50) coolant is compared with several mono nanofluids of Al₂O₃ and Cu, and hybrid nanofluids of Al₂O₃-Cu, Al₂O₃-MWCNT, Al₂O₃-Graphene, Cu-MWCNT, and Cu-Graphene across multiple coolant flow rates from 1–5 LPM. The results demonstrate that nanofluids significantly enhance convective heat transfer and reduce battery temperature compared with the conventional water-glycol coolant. Among the investigated coolants, the Al₂O₃-Cu hybrid nanofluid (0.45–0.45%) operating at 1 LPM achieves the best overall thermo-hydraulic performance with a performance evaluation criterion (PEC) of 1.065. Further analysis of nanoparticle composition ratios shows that a Cu-dominant hybrid mixture (Al₂O₃-Cu: 0.27–0.63%) slightly improves the PEC to 1.0657, indicating marginally superior cooling performance. The findings highlight the potential of hybrid nanofluids as advanced coolants for microchannel-based battery thermal management systems in EVs, particularly under moderate coolant flow conditions. Full article

This study investigates the development of mechanically reprocessed poly(lactic acid) (rPLA) films reinforced with rice husk (RH) and rice husk biochar (RHB) to evaluate their processing behavior, key functional properties, and disintegration under composting conditions. rPLA was produced from PLA through an additional processing cycle to simulate the valorization of industrial PLA waste, while composites containing 1 and 3 wt.% RH or RHB 500 µm sized particles were manufactured by melt extrusion followed by a compression molding process. Reprocessing increased the melt flow index and decreased intrinsic viscosity and viscosimetric molecular weight, evidencing the occurrence of chain scission during mechanical reprocessing. The addition of RH slightly restricted melt flow and promoted higher surface hydrophilicity, whereas RHB showed a filler-loading-dependent effect on melt flow and increased surface hydrophobicity at low content, consistent with its carbonized and less polar nature. Both RH and RHB promote a nucleating effect, with increased crystallinity in RHB-containing films, and tensile tests showing that filler incorporation mainly reduced ductility compared with unfilled rPLA, while stiffness and strength was maintained or exhibited more moderate variations. Despite these contrasting trends in surface properties and thermo-mechanical performance, all formulations achieved complete disintegration within 21 days under composting conditions at laboratory scale level. Overall, RH and RHB provide a viable route to valorize agro-industrial residues in rPLA films and to tune structure–property relationships within the circular economy framework. Full article