Search Results (12)

Heat exchangers are necessary in most engineering systems that move thermal energy from a hot source to a colder location. The development of additive manufacturing technology facilitates the design and optimization of heat exchangers by introducing triply periodic minimal surface (TPMS) structures. TPMSs have shown excellent mechanical and thermal performance, which can improve heat energy transfer efficiency in heat exchangers. This current study intends to design and develop efficient, lightweight heat exchangers for aerospace and space applications. Using the TPMS structure, a porous construction encloses a horizontal tube that circulates heated fluid. Low-temperature water circulates inside a rectangular box that houses the complete system to remove heat from the horizontal pipe. Three porous structures, the gyroid, diamond, and FKS structures, were employed and examined. Porous models with various porosities and surface areas (15 cm² and 24 cm²) were investigated. The results revealed that the gyroid structure exhibits the highest Nusselt number for heat removal (Nu max = 2250), confirming the highest heat transfer and lowest pressure drop among the three structures under investigation. The maximum Nusselt number obtained for the FKS structure is less than 1000, whereas, for the diamond structure, it is near 1250. A linear variation in the average Nusselt number as a function of the structure surface area was found for the FKS and diamond structures. In contrast, nonlinearity was observed in the gyroid structures. Full article

This study investigates the methods for controlling porosity in thermal pipes manufactured using selective laser melting (SLM) technology. Experiments conducted include water permeability tests and surface roughness measurements, which are complemented by SEM image ML-based analysis for pore recognition. The results elucidate the impact of SLM printing parameters on water permeability. Specifically, an increase in hatch and point distances leads to a linear rise in permeability, while higher laser power diminishes permeability. Using machine learning (ML) techniques, precise pore identification on SEM images depicting surface microstructures of the samples is achieved. The average percentage of the surface area containing detected pores for microstructure samples printed with laser parameters (laser power (W) _ hatch distance (µm) _ point distance (µm)) 175_ 80_80 was found to be 5.2%, while for 225_120_120, it was 4.2%, and for 275_160_160, it was 3.8%. Pore recognition was conducted using the Haar feature-based method, and the optimal patch size was determined to be 36 pixels on monochrome images of microstructures with a magnification of 33×, which were acquired using a Leica S9 D microscope. Full article

With the development of microsatellite technology, the heat generated by onboard components is increasing, leading to a growing demand for improved thermal dissipation in small satellites. Metal powder additive manufacturing technology offers the possibility of customizing and miniaturizing heat pipes to meet the specific requirements of small satellites. This article introduces a small-scale heat pipe designed using selective laser melting (SLM) technology. The heat pipe’s material, structure, and internal working fluid were determined based on mission requirements. Subsequently, the SolidWorks 2021 software was used for heat pipe modeling, and the ANSYS 2021R2 finite element analysis software was employed to simulate the heat transfer performance of the designed heat pipe, confirming its feasibility. The heat pipe’s structure was optimized using multi-objective regression analysis, considering various structural parameters, such as the channel diameter, vapor chamber height, and narrow gap width. The simulation results demonstrate that the optimized heat pipe achieved a 10.5% reduction in thermal resistance and an 11.6% increase in equivalent thermal conductivity compared to the original heat pipe. Furthermore, compared to conventional metal heat-conducting rods, the optimized heat pipe showed a 38.5% decrease in thermal resistance and a 62.19% increase in equivalent thermal conductivity. The heat pipe was then fabricated using a 3D printer (EOS M280), and a vacuum experimental system was established to investigate its heat transfer characteristics. The experimental results show that the heat pipe operated most efficiently at a heating power of 20 W, reached its maximum heat transfer capacity at 22 W, and had an optimal fill ratio of 30%. These results highlight the excellent performance of the heat pipe and the promising application prospects for SLM technology in the field of small satellites. 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

This study employed metal additive manufacturing technology to fabricate oscillating heat pipes using SUS316L as the material and conducted related printing parameter experiments and thermal performance tests. The initial experimentation involved testing the relative density and size error of the metal additive manufacturing process. Density measurement was performed using the Archimedes method, and further X-ray CT scanning was utilized to observe the internal structure and compactness. The outcomes indicate that suitable laser parameters yield favorable results in producing oscillating heat pipes, achieving good compactness and minimal dimensional error with proper parameter adjustments. Following relevant pre-processing and post-processing on the oscillating heat pipe, leakage experiments were conducted to ensure experimental accuracy. The oscillating heat pipe had dimensions of 120 mm in length and 51 mm in width, with five turns of 2 mm × 2 mm cross-sectional channels inside. Interval design was employed to address inter-channel thermal interaction commonly encountered in flat heat pipes for comparison. Methanol was selected as the working fluid to investigate the oscillating characteristics and thermal performance under different input powers (20 W, 30 W, 40 W, 60 W, 80 W). The results indicated that the inter-channel spacing can significantly decrease the lateral thermal interaction and enhance the oscillation effect during the operation of the oscillating heat pipe, resulting in improved thermal performance. The experiments demonstrated that at 20 W, the equivalent thermal conductivity of the heat pipes with and without inter-channel spacing was 2428 and 1743 (W/mK), respectively, and at 80 W, it was 2663 and 2511 (W/mK), respectively. These results indicate that reducing thermal interaction can significantly improve the oscillation effect, leading to higher equivalent thermal conductivity at low power. Full article

Among the fire reports caused by seasonal devices registered with the Korea Fire Information Center in 2021, fires caused by heating cables accounted for the largest portion with 350 cases. As a result of analyzing the heating cable fires from 2015 to 2021, we have classified the heating cable fires into four types according to the method of winding the heating wire. First, we hypothesized that the temperature is high when the density is high due to the overlap of the hot wires or when there is a thermal insulating material. We predicted that the temperature would rise through a random game and established a reproducibility test plan. In order to check how heat generation changes depending on the winding method of antifreeze heating cables, we selected 10 manufacturers and checked the temperature characteristics according to the test conditions (Paragraph 11, Paragraph 19.101) of the Technical Regulations for Electrical and Telecommunication Products and Components of Korea (K 10013), tested the four methods mentioned in this thesis and compared and analyzed the results. The experiment results indicate that the temperature of the heater part in antifreeze heating cables was mostly higher than the conditions required by the existing standards in cases 1 to 4. In particular, in the case of No. 5 manufacturer’s sample, the temperature of the heating cable of Case 1 was measured to be the highest at 119.0 °C. In addition, as a result of applying the data engineering reproducibility test results in the framework of the random game λ proposed in this thesis, we have derived the same results as the predicted hypothesis. Case 1 refers to the case where a fire occurs due to the heating cable being wrapped around the water pipe and insulation or taped outside; It is one of the methods that users actually use a lot in the field. Based on experiment, we have concluded that the fire risk is high under the Case 1 condition. Thus, the test conditions in the existing K 10013 Standard need to be strengthened according to the Case 1 condition. Full article

Thermal control systems have been introduced as an important part of electronic devices, enabling thermal management of their electronic components. Loop heat pipe (LHP) is a passive two-phase heat transfer device with significant potential for numerous applications, such as aerospace applications, high-power LEDs, and solar central receivers. Its advantages are high heat transfer capability, low thermal resistance, long-distance heat transfer, and compact structure. The essential role of wick structures on the performance of LHPs has already been highlighted, but no comprehensive review is available that deals with different parameters such as LHP design and wick size, which are largely decisive and effective in achieving a practical level of thermal transmission governed by wick structures. To rely on this necessity, this article summarizes, analyzes, and classifies advancements in the design and fabrication of wick structures. The main conclusion to be drawn after careful monitoring and weighing of the related literature is that LHPs with composites and additively manufactured wicks show a higher heat transfer coefficient than other conventional structures. Indeed, future works should be focused on the design of more structurally efficient wicks, which may allow us to optimize materials and geometrical parameters of wick structure for higher heat transfer through LHPs. Full article

Additive manufacturing (AM) is a key technology for advancing many fields, including electrical machines. It offers unparalleled design freedom together with low material waste and fast prototyping, which is why it has become to focus of many researchers. For electrical machines, AM allows the production of designs with optimized mechanical, electromagnetic and thermal parameters. This paper attempts to give the reader an overview of the existing research and thermal solutions which have been realized with the use of AM. These include novel heat sink and heat exchanger designs, solutions for cooling the machine windings directly, and additively manufactured hollow windings. Some solutions such as heat pipes, which have been produced with AM but not used to cool electrical machines, are also discussed, as these are used in conventional designs and will certainly be used for additively manufactured electrical machines in the future. Full article

The aim of this review is to present the recent developments in heat pipe production, which respond to the current technical problems related to the wide implementation of this technology. A novel approach in HP manufacturing is to utilise hi-tech additive manufacturing techniques where the most complicated geometries are fabricated layer-by-layer directly from a digital file. This technology might be a solution to various challenges that exist in HP production, i.e., (1) manufacturing of complex or unusual geometries HPs; (2) manufacturing complicated and efficient homogenous wick structures with desired porosity, uniform pore sizes, permeability, thickness and where the pores are evenly distributed; (3) manufacturing a gravity friendly wick structures; (4) high customisation and production time; (5) high costs; (6) difficulties in the integration of the HP into a unit chassis that enables direct thermal management of heated element and decrease its total thermal resistance; (7) high weight and material use of the part; (8) difficulties in sealing; (9) deformation of the flat shape HPs caused by the high pressure and uneven distribution of stress in the casing, among others. Full article

The focus of this review is to present the current advances in Loop Heat Pipes (LHP) with flat evaporators, which address the current challenges to the wide implementation of the technology. A recent advance in LHP is the design of flat-shaped evaporators, which is better suited to the geometry of discretely mounted electronics components (microprocessors) and therefore negate the need for an additional transfer surface (saddle) between component and evaporator. However, various challenges exist in the implementation of flat-evaporator, including (1) deformation of the evaporator due to high internal pressure and uneven stress distribution in the non-circular casing; (2) heat leak from evaporator heating zone and sidewall into the compensation chamber; (3) poor performance at start-up; (4) reverse flow through the wick; or (5) difficulties in sealing, and hence frequent leakage. This paper presents and reviews state-of-the-art LHP technologies; this includes an (a) review of novel manufacturing methods; (b) LHP evaporator designs; (c) working fluids; and (d) construction materials. The work presents solutions that are used to develop or improve the LHP construction, overall thermal performance, heat transfer distance, start-up time (especially at low heat loads), manufacturing cost, weight, possibilities of miniaturization and how they affect the solution on the above-presented problems and challenges in flat shape LHP development to take advantage in the passive cooling systems for electronic devices in multiple applications. Full article

Scaling commonly occurs at pipe wall during landfill leachate collection and transportation, which may give rise to pipe rupture, thus posing harm to public health and environment. To prevent scaling, this study prepared a low surface energy nanocomposite by incorporating silicone-acrylate polymer and hydrophobically modified nano-SiO₂ into the high-density polyethylene (HDPE) substrate. Through the characterization of contact angle, scanning electron microscopy and thermogravimetry, the results showed that the prepared composite has low wettability and surface free energy, excellent thermal stability and acid-base resistance. In addition, the prepared composite was compared with the commercial HDPE pipe material regarding their performance on anti-scaling by using an immersion test that places their samples into a simulated landfill leachate. It was apparent that the prepared composite shows better scaling resistance. The study further expects to provide insight into pipe materials design and manufacture, thus to improve landfill leachate collection and transportation. Full article

Hospitals are very attractive for Combined Heat and Power (CHP) applications, due to their high and continuous demand for electric and thermal energy. However, both design and control strategies of CHP systems are usually based on an empiric and very simplified approach, and this may lead to non-optimal solutions. The paper presents a novel approach based on the dynamic simulation of a trigeneration system to be installed in a hospital located in Puglia (South Italy), with around 600 beds, aiming to investigate the energy and economic performance of the system, for a given control strategy (electric-load tracking). The system includes a natural gas fired reciprocating engine (with a rated power of 2.0 MW), a single-stage LiBr-H₂O absorption chiller (with a cooling capacity of around 770 kW), auxiliary gas-fired boilers and steam generators, electric chillers, cooling towers, heat exchangers, storage tanks and several additional components (pipes, valves, etc.). Suitable control strategies, including proportional–integral–derivative (PID) and ON/OFF controllers, were implemented to optimize the trigeneration performance. The model includes a detailed simulation of the main components of the system and a specific routine for evaluating the heating and cooling demand of the building, based on a 3-D model of the building envelope. All component models were validated against experimental data provided by the manufacturers. Energy and economic models were also included in the simulation tool, to calculate the thermoeconomic performance of the system. The results show an excellent economic performance of the trigeneration system, with a payback period equal to 1.5 years and a profitability index (ratio of the Net Present Value to the capital cost) equal to 3.88, also due to the significant contribution of the subsidies provided by the current Italian regulation for CHP systems (energy savings certificates). Full article