Indian Institute of Technology, Patna

Department of Mechanical Engineering

ME- 5107: Thermo-Fluid Lab-I

Lab Report - 1
COMPOSITE SLAB
Lab In-charge:
Dr. Ajay Kumar Yadav
Dr. Chetan Kumar Patel

Submitted by: -
Pushkar Varma
Roll Number: 2411ME09
Contents:

1. Objective 1
2. Block Diagram 1
3. Introduction 1
4. Theory 1
5. Experimental Procedure 2
6. Observation and Calculation 3
7. Results and Discussion 5
8. Precaution 6
9. Sources of Error 6
OBJECTIVE:
1. To determine the overall thermal conductivity of the composite slab.
2. To determine the thermal conductivity of different layers of composite slab.

BLOCK DIAGRAM:

Fig-1

INTRODUCTION:
The composite wall consists of multiple layers of different materials (in this case, Mild Steel,
Bakelite, and Press Wood) stacked together. A central heater is placed between the layers, and
heat flows radially outward through the layers. The heat transfer is assumed to be one-
dimensional, meaning heat flows only in the axial direction (along the thickness of the slabs)
and not in the radial direction .

THEORY:
The one-dimensional heat transfer rate due to conduction is governed by Fourier's Law of Heat
Conduction:
𝑑𝑇
𝑄 = −𝐾𝐴 𝑑𝑋

Where:

• Q = Heat transfer rate (W)

• k = Thermal conductivity of the material (W/m-K)

• A = Cross-sectional area perpendicular to the direction of heat flow (m²)

𝑑𝑇
• = Temperature gradient along the direction of heat flow (K/m)
𝑑𝑋

1
For a slab of thickness L, Fourier's Law can be integrated to give:
𝑇1 −𝑇2
𝑄 = −𝐾𝐴 𝐿

Where:

• 𝑇1 𝑎𝑛𝑑 𝑇2 = Temperatures at the two faces of the slab (K)

• L = Thickness of the slab (m)

Thermal Resistance Analogy

The heat conduction process can be analogously compared to an electrical circuit, where:

• Heat flow (Q) is analogous to electric current.

• Temperature difference (𝑇1 − 𝑇2 ) is analogous to voltage.

• Thermal resistance (Rth) is analogous to electrical resistance.

The thermal resistance for a slab is given by:

𝐿
Rth =𝐾𝐴

For a composite wall with multiple layers, the total thermal resistance is the sum of the individual
thermal resistances of each layer (since the layers are in series):

𝐿 𝐿 𝐿
𝑅𝑡ℎ = 𝑅𝑀𝑆 + 𝑅𝐵𝑎𝑘𝑒𝑙𝑖𝑡𝑒 + 𝑅𝑤𝑜𝑜𝑑 = 𝐾 1𝐴 + 𝐾 2𝐴 + 𝐾 3𝐴
1 2 3

Where:

• 𝑅𝑀𝑆 , 𝑅𝐵𝑎𝑘𝑒𝑙𝑖𝑡𝑒 𝑎𝑛𝑑 𝑅𝑤𝑜𝑜𝑑 = Thermal resistances of Mild Steel, Bakelite, and Press Wood,
respectively.

• L1 ,L2 and L3 = Thicknesses of Mild Steel, Bakelite, and Press Wood, respectively.

• K1,K2 and K3 = Thermal conductivities of Mild Steel, Bakelite, and Press Wood, respectively.

Heat Flow in Composite Wall

The heat flow through the composite wall is assumed to be symmetric, meaning half of the total heat
generated by the central heater flows to one side, and the other half flows to the opposite side.
Therefore, the heat flow through each side is:

Q1 = Q2 = Q/2

2
The temperature drops across each layer can be used to calculate the thermal resistances of the
individual layers:

(𝑇1 − 𝑇3 ) (𝑇2 − 𝑇4 ) (𝑇3 − 𝑇5 ) (𝑇4 − 𝑇6 ) (𝑇5 − 𝑇7 ) (𝑇6 − 𝑇8 )

𝑅𝑀𝑆 = = , 𝑅𝐵𝑎𝑘𝑒𝑙𝑖𝑡𝑒 = = , 𝑅𝑤𝑜𝑜𝑑 = =
𝑄/2 𝑄/2 𝑄/2 𝑄/2 𝑄/2 𝑄/2

EXPERIMENTAL SETUP:
The composite wall consists of three layers—Mild Steel, Bakelite, and Press Wood—with a
central heater generating heat that flows outward through both sides. Thermocouples placed
at the interfaces measure temperature variations across the layers. A power supply with a
dimmerstat controls the heat input, while a voltmeter and ammeter help calculate the total
heat supplied. The experiment runs until a steady-state condition is reached, where heat flow
stabilizes, and temperatures remain constant.

EXPERIMENTAL PROCEDURE:
1. Set Up the Apparatus: Ensure the composite wall (Mild Steel, Bakelite, and Press
Wood) is properly assembled with the central heater and thermocouples in place.
Press the slabs together to remove any air gaps.
2. Connect the Instruments: Attach the heater to the power supply and check that the
voltmeter, ammeter, and dimmerstat are correctly connected and working.
3. Start Heating: Turn on the power supply and keep the dimmerstat at zero initially.
Slowly increase the voltage but keep it below 70V to prevent overheating the heater.
4. Measure Heat Input: Read the voltage and current from the voltmeter and ammeter,
then calculate the heat supplied using the formula Q=V×IQ = V \times IQ=V×I.
5. Record Temperatures: Use the selector switch to read temperatures from all
thermocouples (T₁ to T₈). Take readings every 10 minutes until temperatures stop
changing (steady-state condition).
6. Achieve Steady-State: Once the system stabilizes, note the final temperature,
voltage, and current readings.
7. Calculate Thermal Conductivity: Using the recorded data, calculate the thermal
conductivity of each material and the overall conductivity of the composite wall.
8. Analyze and Conclude: Plot the temperature gradient, compare calculated values
with standard data, check for errors, and discuss any deviations. Finally, summarize
the key findings of the experiment.

OBSERVATION & CALCULATION:

Given Data:
1 Diameter of composite slab 200 mm
2 Thickness of mild steel slab (2 Nos.) 22 mm
3 Thickness of bakelite slab (2 Nos.) 19 mm
4 Thickness of press wood slab (2 Nos.) 12 mm
5 Thermal conductivity of mild steel (standard value at 309 K) 59 W/m-K
6 Thermal conductivity of bakelite (standard value at 300 K) 1.4 W/m-K
7 Thermal conductivity of wood (standard value at 300 K) 0.055 W/m-K

3
 S Voltmeter Ammeter Heat T1 T2 T3 T4 T5 T6 T7 T8
No. Reading Reading Supplied (°C) (°C) (°C) (°C) (°C) (°C) (°C) (°C)
(V) (I) Q= VI
(W)
1. 70 0.697 48.8 51.5 50.9 50.9 50.4 35.7 34.7 28.5 28.6
2. 70 0.697 48.8 52.8 52.1 52.2 51.7 36.5 35.4 28.8 28.9
3. 70 0.697 48.8 54.3 52.6 53.7 53.2 37.4 36.2 29.1 29.2
4. 70 0.697 48.8 55.8 55.1 55.1 54.6 38.2 37 29.5 29.6
S Voltmeter Ammeter Heat T1 T2 T3 T4 T5 T6 T7 T8
No. Reading Reading Supplied (°C) (°C) (°C) (°C) (°C) (°C) (°C) (°C)
(V) (I) Q= VI
(W)
1. 60 0.606 36.3 40 39.6 39.6 39.1 29.7 28.9 26.2 26.3
2. 60 0.606 36.3 41.2 40.7 40.7 40.2 30.3 29.4 26.3 26.4
3. 60 0.606 36.3 42.5 42 42 41.5 31.1 30.1 26.6 26.7
4. 60 0.606 36.3 43.7 43.2 43.2 42.7 31.8 30.8 26.8 26.9

S Voltmeter Ammeter Heat T1 T2 T3 T4 T5 T6 T7 T8

No. Reading Reading Supplied (°C) (°C) (°C) (°C) (°C) (°C) (°C) (°C)
(V) (I) Q= VI
(W)

1. 65 0.645 41.92 45.7 45.1 45.2 44.7 32.8 31.7 27.1 27.5
2. 65 0.645 41.92 47.3 46.7 46.8 46.3 33.6 32.5 27.5 27.6
3. 65 0.645 41.92 48.5 47.9 48 47.5 34.3 33.2 27.8 27.9
4. 65 0.645 41.92 49.6 49 49 48.6 35 33.8 28.1 28.2

CALCULATION:

(𝑇12 − 𝑇34 ) (39.8 − 39.35)

𝑅𝑀𝑆 = = = 0.0248
𝑄 18.15
2
(𝑇34 −𝑇56 ) (39.35−29.3)
𝑅𝐵𝑎𝑘𝑒𝑙𝑖𝑡𝑒 = 𝑄 = = 0.554
18.15
2

(𝑇56 −𝑇78 ) (29.3−26.25)

𝑅𝑤𝑜𝑜𝑑 = = = 0.168
𝑄/2 18.15

(𝑇1 +𝑇2 ) 40+39.6

𝑇12 = = = 39.8
2 2

(𝑇3 +𝑇4 ) 39.6+39.1

𝑇34 = = = 39.35
2 2

(𝑇5 +𝑇6 ) 29.7+28.9

𝑇56 = = = 29.3
2 2

4
 (𝑇7 +𝑇8 ) 26.2+26.3
𝑇78 = = = 26.25
2 2

𝐿1 0.022 0.022
𝐾𝑀𝑆 = = 𝛱 = 𝛱 = 28.24 W/m-K
𝑅𝑀𝑆 𝐴 0.0.0248× ×(𝐷2 ) 0.0248× ×(0.22 )
4 4

𝐿2 0.019 0.019
𝐾𝑏𝑎𝑘𝑒𝑙𝑖𝑡𝑒 = = 𝛱 = 𝛱 = 1.092 W/m-K
𝑅𝑏𝑎𝑘𝑒𝑙𝑖𝑡𝑒 𝐴 0.554× ×(𝐷2 ) 0.554× ×(0.22 )
4 4

𝐿3 0.012 0.012
𝐾𝑤𝑜𝑜𝑑 = = 𝛱 = 𝛱 = 2.274 W/m-K
𝑅𝑤𝑜𝑜𝑑 𝐴 0.168× ×(𝐷2 ) 0.168× ×(0.22 )
4 4

The overall thermal conductivity can be determined by evaluating the equivalent thermal
resistance:

𝑅𝑡ℎ = 𝑅𝑚𝑠 + 𝑅𝑏𝑎𝑘𝑒𝑙𝑖𝑡𝑒 + 𝑅𝑤𝑜𝑜𝑑

𝑅𝑡ℎ = 0.0248 + 0.554 + 0.168 = 0.747

𝐿 𝐿1 𝐿2 𝐿3
= + +
𝐾𝑒𝑞 𝐴 𝑅𝑚𝑠 𝐴 𝑅𝑏𝑎𝑘𝑒𝑙𝑖𝑡𝑒 𝐴 𝑅𝑤𝑜𝑜𝑑𝐴

𝐿 𝐿1 𝐿2 𝐿3
= + +
𝐾𝑒𝑞 𝑅𝑚𝑠 𝑅𝑏𝑎𝑘𝑒𝑙𝑖𝑡𝑒 𝑅𝑤𝑜𝑜𝑑

0.022+0.019+0.012 0.022 0.019 0.012

= + +
𝐾𝑒𝑞 0.0248 0.554 0.168

𝐾𝑒𝑞 = 0.0533 W/m-K

RESULTS AND DISCUSSIONS:

1. Percentage Errors:

(𝐾𝑀𝑆 )𝑠𝑡𝑑 − (𝐾𝑀𝑆 )𝑐𝑎𝑙 59 − 28.24

Percentage Error = | |=| | × 100 = 52.13 %
(𝐾𝑀𝑆 )𝑠𝑡𝑑 59

(𝐾𝐵𝑎𝑘 )𝑠𝑡𝑑 − (𝐾𝐵𝑎𝑘 )𝑐𝑎𝑙 1.4 − 1.092

Percentage Error = | |=| | × 100 = 22 %
(𝐾𝐵𝑎𝑘 )𝑠𝑡𝑑 1.4

(𝐾𝑊𝑜𝑜𝑑 )𝑠𝑡𝑑 − (𝐾𝑊𝑜𝑜𝑑 )𝑐𝑎𝑙 0.055 − 2.274

Percentage Error = | |=| | × 100 = 4034.45%
(𝐾𝑊𝑜𝑜𝑑 )𝑠𝑡𝑑 0.055

2. Temperature Gradient Curve:

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 Fig:-Temperature Gradient in Composite Wall

The possible reason for deviation of calculated value of conductivity from

standard value is:
i. Variable heat flux in the setup.
ii. Improper insulation.
iii. Fluctuation in power supply.

PRECAUTIONS:
1. Start with Zero Heat: Always begin with the dimmerstat at zero and slowly increase
heat to avoid sudden spikes that could damage the heater.
2. No Air Gaps: Make sure the slabs are tightly pressed together, as small gaps can trap
air and give wrong temperature readings.
3. Handle Sensors Carefully: Avoid touching or moving the thermocouples during the
experiment, as this can mess up the temperature readings.
4. Watch the Voltage: Keep the voltage under 70V to prevent overheating and damage
to the heater. Check the voltmeter and ammeter regularly.
5. Use the Switch Gently: When switching between thermocouples to record
temperatures, do it carefully to avoid misalignment or damage.

SOURCES OF ERRORS:
1. Heat Loss to Air: If the setup isn’t well insulated, some heat escapes instead of passing
through the wall, causing errors.
2. Tiny Gaps Between Layers: Even small air gaps between metal, Bakelite, and wood act
like insulation, slowing down heat flow and giving wrong results.
3. Faulty Temperature Sensors: If the thermocouples aren’t calibrated correctly, they
might show incorrect temperature readings.
4. Uneven Heating: If the heater doesn’t distribute heat evenly, some areas get hotter than
others, making the readings inaccurate.
5. Rushing the Experiment: If we take readings before the system settles into steady state,
the data won’t be reliable.