Prediction of the maximum heat transfer capability of two-phase heat spreaders – Experimental validation

The present paper is devoted to an experimental study to determine the thermal behaviour of a two-phase heat spreader (TPHS) with micro-grooves. The proposed application is the cooling of fuel cell systems. This TPHS aims at reducing the volume of actual cooling systems and to homogenize the temperature in the hearth of fuel cells. The TPHS is flat with a wide evaporating area (190 × 90 mm²) compared to the condenser area (30 × 90 mm²). It has been tested with three working fluids: water, methanol and n-pentane. Experimental results obtained with methanol show a temperature difference lower than 1.6 K on the entire evaporator area for a heat transfer rate equal to 85 W and a working temperature equal to 70 °C. The TPHS has been tested in both horizontal and vertical favourable orientation (thermosyphon orientation). The temperature field is similar in both cases for heat transfer rates lower than 155 W. In horizontal orientation, a confocal microscope is used to measure the meniscus curvature radius along the grooves. A two-phase flow model allowing the calculation of the meniscus radius, the liquid and vapour pressures and the liquid and vapour velocities along the TPHS is developed. The comparison between experimental and model results shows the good ability of the numerical model to predict the meniscus curvature radii from which the maximum heat transfer capability of the TPHS is depending.     

Effect of non-uniform heating on the performance of the microchannel heat sinks

The present study experimentally investigates the performance of a 2-pass microchannel heat sink subject to non-uniform heating. The size of the microchannel heat sink is 132 mm × 82 mm × 6 mm with a rectangular channel of 1 mm × 1 mm. Three independent heaters having identical size (96 mm × 38.5 mm × 1 mm) is placed consecutively below the microchannel heat sink. Two kinds of manifolds are used for testing of the microchannel, one with a side entrance (type A) and the other with a front entrance (type B). Test results show that both maximum temperature and average temperature rise with the total input power, and this is applicable for both manifolds. For uniform heating condition, the maximum temperature for type B manifold is much lower than that for type A manifold due to a better flow distribution and heat transfer performance. The pressure drop is slightly reduced with the rise of supplied power. For non-uniform heating, the maximum temperature and the average temperature depend on the location of heaters. For the same supplied power with non-uniform heating, it is found that heater being placed at the inlet of the microchannel will give rise to a higher maximum temperature than that being placed at the rear of the heat sink. This phenomenon is especially pronounced when the inlet flowrate is comparatively small and becomes less noted as the inlet flowrate is increased to 0.7 L/min.     

Plume separation from an adiabatic horizontal thin fin placed at different heights on the sidewall of a differentially heated cavity

The separation of plumes from an adiabatic horizontal thin fin attached to a sidewall of a differentially heated cavity at quasi-steady stage is experimentally and numerically studied at three Rayleigh numbers (0.92 × 10⁹, 1.84 × 10⁹ and 3.68 × 10⁹) and over a range of fin positions. Regular plume separation is observed over the present range of parameters during the quasi-steady stage. Both experimental and numerical results reveal that the plume separation frequency increases with the Rayleigh number and decreases with the fin height measured from the leading edge. A higher Rayleigh number leads to a more unstable flow above the horizontal thin fin which in turn leads to a higher plume separation frequency. The decrease of the plume separation frequency with the increasing fin height is mainly due to the reduction of the adverse temperature gradient in the unstable layer above the thin fin as a result of the cavity-wide temperature stratification. It is further revealed that the heat transfer through the sidewall is improved by the presence of the thin fin. An optimum fin height for maximum heat transfer enhancement has been identified for the case with a Rayleigh number of 0.92 × 10⁹. For the other two higher Rayleigh number cases considered in this study, the heat transfer through the sidewall monotonically decreases with the fin height.     

Experimental investigation of capillary-assisted evaporation on the outside surface of horizontal tubes

Capillary-assisted evaporation is a typical heat transfer method in heat pipes which is characterized by high evaporation coefficient due to extremely thin liquid film. This paper introduces such a micro-scale heat transfer method into normal-scale applications. A series of enhanced heat transfer tubes with circumferential rectangular micro-grooves on the outside surfaces have been experimentally investigated. The aim is to investigate the influence of the tubes’ geometries and operating parameters on the evaporation heat transfer coefficients. In the experiment, the tested tubes are hold horizontally and the bottom surfaces are immersed into a pool of liquid. The heat is added to the thin liquid film inside the micro-grooves through the heating fluid flowing inside the tubes. The factors influencing the capillary-assisted evaporation performance, such as the immersion depth, evaporation pressure, superheating degree, etc. are considered. The experimental results have indicated that there is a positive correlation between the evaporation heat transfer coefficient and evaporation pressure, and negative for the superheating and immersion depth. For water, under the evaporation saturated temperature of 5.0 ± 0.1 °C, the superheating of 4.0 ± 0.1 °C and the dimensionless liquid level of 1/2, the film side evaporation heat transfer coefficients are 3100–3500 W/m² K, which are equivalent to those of the falling film evaporator in LiBr–water absorption machine (2800–4500 W/m² K [Y.Q. Dai, Y.Q. Zheng, LiBr–water Absorption Machine, first ed., Chinese National Defence Industry Press, Beijing, China, 1980.]).     

Evaluation of convective heat transfer coefficient of various crops in cyclone type dryer

In this paper, an attempt was made to evaluate the convective heat transfer coefficient during drying of various crops and to investigate the influences of drying air velocity and temperature on the convective heat transfer coefficient. Drying was conducted in a convective cyclone type dryer at drying air temperatures of 60, 70 and 80 °C and velocities of 1 and 1.5 m/s using rectangle shaped potato and apple slices (12.5 × 12.5 × 25 mm) and cylindrical shaped pumpkin slices (35 × 5 mm). The temperature changes of the dried crops and the temperature of the drying air were measured during the drying process. It was found that the values of convective heat transfer coefficient varied from crop to crop with a range 30.21406 and 20.65470 W/m² C for the crops studied, and it was observed that the convective heat transfer coefficient increased in large amounts with the increase of the drying air velocity but increased in small amounts with the rise of the drying air temperature.     

Heat transfer during condensation of moving steam in a narrow channel

The paper presents the results of experimental investigation of heat transfer and hydrodynamics during condensation of moving steam in a narrow channel of square cross-section 2 mm × 2 mm. The channel had a serpentine shape, the channel length was 660 mm. An experimental cell simulated conditions of heat transfer in the condenser of loop heat pipes. The steam velocity at the channel inlet ranged from 13 to 52 m/s, the pressure was 1 atm. The temperature of the cooling water varied from 70 to 95 °C. The annular flow pattern was noted in the whole range of the regime parameters. There was a clear boundary between the condensation zone and the zone occupied by the condensed phase downstream. Temperature has measured along the channel, and the heat-transfer coefficients have been determined. The coefficient values varied from 10,000 to 55,000 W/K m² depending on the steam velocity at the channel inlet and the cooling temperature. The efficiency of the condenser – heat exchanger has been investigated.     

Sintered porous heat sink for cooling of high-powered microprocessors for server applications

This paper experimentally investigates the sintered porous heat sink for the cooling of the high-powered compact microprocessors for server applications. Heat sink cold plate consisted of rectangular channel with sintered porous copper insert of 40% porosity and 1.44 × 10^?11 m² permeability. Forced convection heat transfer and pressure drop through the porous structure were studied at Re ? 408 with water as the coolant medium. In the study, heat fluxes of up to 2.9 MW/m² were successfully removed at the source with the coolant pressure drop of 34 kPa across the porous sample while maintaining the heater junction temperature below the permissible limit of 100 ± 5 °C for chipsets. The minimum value of 0.48 °C/W for cold plate thermal resistance (R_cp) was achieved at maximum flow rate of 4.2 cm³/s in the experiment. For the designed heat sink, different components of the cold plate thermal resistance (R_cp) from the thermal footprint of source to the coolant were identified and it was found that contact resistance at the interface of source and cold plate makes up 44% of R_cp and proved to be the main component. Convection resistance from heated channel wall with porous insert to coolant accounts for 37% of the R_cp. With forced convection of water at Re = 408 through porous copper media, maximum values of 20 kW/m² K for heat transfer coefficient and 126 for Nusselt number were recorded. The measured effective thermal conductivity of the water saturated porous copper was as high as 32 W/m K that supported the superior heat augmentation characteristics of the copper–water based sintered porous heat sink. The present investigation helps to classify the sintered porous heat sink as a potential thermal management device for high-end microprocessors.     

Estimation of heat transfer coefficient and phase transformation latent heat by modified pattern search method

This paper describes in detail the measurement of the overall heat transfer coefficient and phase transformation latent heat by modified pattern search method (PSM). By introducing the pattern search algorithm into finite element analysis, the measurement of heat transfer coefficients and phase transformation latent heat can be simplified as recording the temperature with time. Comparison of the measurements by PSM and temperature gradient method (TGM) shows that PSM can evaluate the overall heat transfer coefficient accurately. Experiments and simulations show that bainite transformation latent heat in 26NiCrMoV10-10 steel is about − 90.5 J/g, and the latent heat increases the surface temperature of a cylindrical specimen by a maximum of 76 °C. Error analysis shows that the highest difference between calculated temperature and measured temperature is 11.7 °C, which verifies that the heat transfer coefficient and phase transformation latent heat estimated by PSM are accurate, and that the pattern search method is reliable.     

Subcooled flow boiling heat transfer and associated bubble characteristics of FC-72 on a heated micro-pin-finned silicon chip

Experiments are conducted here to investigate subcooled flow boiling heat transfer and associated bubble characteristics of FC-72 on a heated micro-pin-finned silicon chip flush-mounted on the bottom of a horizontal rectangular channel. In the experiments the mass flux is varied from 287 to 431 kg/m² s, coolant inlet subcooling from 2.3 to 4.3 °C, and imposed heat flux from 1 to 10 W/cm². Besides, the silicon chips contain three different geometries of micro-structures, namely, the smooth, pin-finned 200 and pin-finned 100 surfaces. The pin-finned 200 and 100 surfaces, respectively, contain micro-pin-fins of size 200 μm × 200 μm × 70 μm (width × length × height) and 100 μm × 100 μm × 70 μm. The measured data show that the subcooled flow boiling heat transfer coefficient is reduced at increasing inlet liquid subcooling but is little affected by the coolant mass flux. Besides, adding the micro-pin-fin structures to the chip surface can effectively raise the single-phase convection and flow boiling heat transfer coefficients. Moreover, the mean bubble departure diameter and active nucleation site density are reduced for rises in the FC-72 mass flux and inlet liquid subcooling. Increasing coolant mass flux or reducing inlet liquid subcooling results in a higher mean bubble departure frequency. Furthermore, larger bubble departure diameter, higher bubble departure frequency, and higher active nucleation site density are observed as the imposed heat flux is increased. Finally, empirical correlations for the present data for the heat transfer and bubble characteristics in the FC-72 subcooled flow boiling are proposed.     

Combustion of micro aluminum–water mixtures

An experimental investigation on the combustion behavior of micro-sized aluminum (μAl)–water mixtures was conducted. It was easily ignited and self-deflagrated on μAl and liquid water when using a paper shell tube. Linear burning rates of quasi-homogeneous mixtures of μAl and liquid water as a function of pressure, mixture composition, density and environment gas medium were measured. Steady-state burning rates were obtained at room temperature using a windowed vessel for a pressure range of 1–80 bar in a nitrogen atmosphere, particle size of 0.5 × 30 × 30 μm and overall mixture equivalence ratios from 0.67 to 2.0. The pressure exponent was obtained as 0.47 at room temperature and compared to the case of nano-sized aluminum (nAl) and liquid water. When a wire was inserted into the sample, for increasing local heat transfer, burning rates were found to be faster.     

Effects of duct inclination angle on thermal entrance region of laminar and transition mixed convection

Experimental investigation was performed on the mixed convection heat transfer of thermal entrance region in an inclined rectangular duct for laminar and transition flow. Air flowed upwardly and downwardly with inclination angles from ?90° to 90°. The duct was made of duralumin plate and heated with uniform heat flux axially. The experiment was designed for determining the effects of inclination angles on the heat transfer coefficients and friction factors at seven orientations (θ = ? 90°, ?60°, ?30°, 0°, 30°, 60° and 90°), six Reynolds numbers (Re ≈ 420, 840, 1290, 1720, 2190 and 2630) within the range of Grashof numbers from 6.8 × 10³ to 4.1 × 10⁴. The optimum inclination angles that yielded the maximum heat transfer coefficients decreased from 30° to ?30° with the increase of Reynolds numbers from 420 to 1720. The heat transfer coefficients first increased with inclination angles up to a maximum value and then decreased. With further increase in Reynolds numbers, the heat transfer coefficients were nearly independent of inclination angles. The friction factors decreased with the increase of inclination angles from ?90° to 90° when Reynolds numbers ranged from 420 to 1290, and independent of inclination angles with higher Reynolds numbers.     

3-D Numerical study on the correlation between variable inclined fin angles and thermal behavior in plate fin-tube heat exchanger

In this study, the heat transfer enhancement and pressure drop values of seven different fin angles with plain fin-tube heat exchangers were investigated. The numerical simulation of the fin-tube heat exchanger was performed by using a three dimensional (3-D) numerical computation technique. Therefore, a CFD computer code, the FLUENT was used to solve the equation for the heat transfer and pressure drop analyses in the fin-tube heat exchanger. The model drawing was created and meshed by using GAMBIT software. The heat transfer and pressure drop values of the vertical fin angle (θ = 0°) were provided to compare with variable inclined fin angles (θ = 5°, 10°, 15°, 20°, 25°, 30°). The heat transfer values were normalized to compare all cases. For inclined fin angle θ = 30°, which is the optimum angle, the maximum heat transfer enhancement per segment was obtained 1.42 W (the normalized value 105.24%), the maximum loss power associated with pressure drop per segment was only 0.54 mW.     

Analysis of combined thermal and magnetic convection ferrofluid flow in a cavity

A numerical analysis of the magnetic gradient and thermal buoyancy induced cavity ferrofluid flow is conducted by a semi-implicit finite element method. The physical model for a square cavity containing two different temperature side walls and a magnet near bottom wall is described by mass, momentum and energy equations. Conditions for the fixed Prandtl number, Rayleigh number and different ferro-hydrodynamic interaction parameter are studied for 5 × 10⁸ ≤ β ≤ 1.6 × 10¹⁰. Results show the flow strength increases with the strengthening magnetic field. However, the side-wall heat transfer rate presents a decrease trend with the increase in magnetic field strength, for the magnet located near the bottom central area evokes the circulation to move toward the central portion. In summary, a proper choice of magnet strength and location can adjust the flow field and local heat transfer rate to fit the practical application.     

A fast response heat pump water heater using thermostat made from shape memory alloy

The heat pump water heater produces hot water so slow at low ambient temperature that it frequently could not meet the hot water load demand in winter. The present study develops a fast response heat pump water heater (FRHP) designed with two separate tanks (supply and holding tank) which are connected by a thermostat made from shape memory alloy (SMAV). The SMAV is a mechanical heat-sensitive device made from shape memory alloy which keeps the valve closed when the water temperature is not high enough. This will isolate the tanks and let the vapor compression cycle heat up the supply tank only. The speed of temperature rise thus is increased. The SMAV will open and induce a natural circulation between two tanks to transfer the heat from the supply tank to the holding tank, when water is heated to a designated temperature. A 100 l FRHP was built and tested in the present study. The experimental results showed that the temperature response speed of the supply tank, before SMAV is opened, reaches 1.056 °C/min and the holding tank, after SMAV is opened, reaches 0.828 °C/min at ambient temperature 20 °C. The FRHP will heat up 50 l water in the supply tank with 30 °C temperature rise within 40 min in winter which is acceptable in domestic application. The energy consumption is in the range 0.008–0.016 kWh/l of hot water at about 55 °C.     

Experimental study of saturated flow boiling heat transfer in an array of staggered micro-pin-fins

This study concerns water saturated flow boiling heat transfer in an array of staggered square micro-pin-fins having a 200 × 200 μm² cross-section by a 670 μm height. Three inlet temperatures of 90, 60, and 30 °C, six mass velocities for each inlet temperature, ranging from 183 to 420 kg/m² s, and outlet pressures between 1.03 and 1.08 bar were tested. Heat fluxes ranged from 23.7 to 248.5 W/cm². Heat transfer coefficient was fairly constant at high quality, insensitive to both quality and mass velocity. Heat transfer was enhanced by inlet subcooling at low quality. Possible heat transfer mechanism was discussed.     

Effects of surfactant additive on flow boiling over a microheater under pulse heating

An experimental investigation has been carried out to study effects of surfactant additive on microscale boiling under pulse heating over a Pt microheater (140 × 100 μm²) fabricated in a trapezoidal microchannel (600 μm in width and 150 μm in depth). Experiments are carried out for six different surfactant concentrations of Triton X-100 ranging from 47 ppm to 2103 ppm, for mass flux in the range from 45 kg/m² s to 225 kg/m² s, pulse width in the range from 50 μs to 2 ms, and heat flux in the range from 3 MW/m² to 65 MW/m². As in existing work on pool boiling under steady heating, it is found that nucleate boiling becomes more vigorous and heat transfer is enhanced greatly with the addition of surfactant with maximum boiling heat transfer occurs at the critical micelle concentration (cmc). Furthermore, these maximum values of boiling heat transfer coefficient increase with decreasing pulse width. When concentration is below cmc, the heat flux needed for nucleation increases with increasing concentration and the nucleation temperature is reduced. When concentration is higher than cmc, the boiling heat transfer coefficient decreases and nucleation temperature is higher than that of pure water.     

Experimental investigation of mixed convection heat transfer in a rectangular channel with discrete heat sources at the top and at the bottom

Mixed convection heat transfer in a top and bottom heated rectangular channel with discrete heat sources has been investigated experimentally for air. The lower and upper surfaces of the channel were equipped with 8 × 4 flush-mounted heat sources subjected to uniform heat flux. Sidewalls, the lower and upper walls were insulated and adiabatic. The experimental study was made for an aspect ratio of AR = 6, Reynolds numbers 955 ≤ Re_Dh ≤ 2220 and modified Grashof numbers Gr* = 1.7 × 10⁷ to 6.7 × 10⁷. From experimental measurements, surface temperature and Nusselt number distributions of the discrete heat sources were obtained for different Grashof numbers. Furthermore, Nusselt number distributions were calculated for different Reynolds numbers. Results show that surface temperatures increase with increasing Grashof number. The row-averaged Nusselt numbers first decrease with the row number and then, due to the increase in the buoyancy affected secondary flow and the onset of instability, they show an increase towards the exit as a result of heat transfer enhancement.     

Saturated flow boiling heat transfer and associated bubble characteristics of FC-72 on a heated micro-pin-finned silicon chip

An experiment is carried out here to investigate flow boiling heat transfer and associated bubble characteristics of FC-72 on a heated micro-pin-finned silicon chip flush-mounted in the bottom of a horizontal rectangular channel. Besides, three different micro-structures of the chip surface are examined, namely, the smooth, pin-finned 200 and pin-finned 100 surfaces. The pin-finned 200 and 100 surfaces, respectively, contain micro-pin-fins of size 200 μm × 200 μm × 70 μm (width × length × height) and 100 μm × 100 μm × 70 μm. The pitch of the fins is equal to the fin width for both surfaces. The effects of the FC-72 mass flux, imposed heat flux, and surface micro-structures of the silicon chip on the FC-72 saturated flow boiling characteristics are examined in detail. The experimental data show that an increase in the FC-72 mass flux causes a delay in the boiling incipience. However, the flow boiling heat transfer coefficient is not affected by the coolant mass flux. But adding the micro-pin-fin structures to the chip surfaces can effectively enhance the single-phase convection and flow boiling heat transfer. Moreover, the mean bubble departure diameter and active nucleation site density are reduced for a rise in the FC-72 mass flux. A higher coolant mass flux results in a higher mean bubble departure frequency. Furthermore, larger bubble departure diameter, higher bubble departure frequency, and higher active nucleation site density are observed at a higher imposed heat flux. We also note that adding the micro-pin-fins to the chips decrease the bubble departure diameter and increase the bubble departure frequency. However, the departing bubbles are larger for the pin-finned 100 surface than the pin-finned 200 surface but the bubble departure frequency exhibits an opposite trend. Finally, empirical equations to correlate the present data for the FC-72 single-phase liquid convection and saturated flow boiling heat transfer coefficients and for the bubble characteristics are provided.     

Experimental analysis of flow and heat transfer in a miniature porous heat sink for high heat flux application

A novel miniature porous heat sink system was presented for dissipating high heat fluxes of electronic device, and its operational principle and characteristics were analyzed. The flow and heat transfer of miniature porous heat sink was experimentally investigated at high heat fluxes. It was observed that the heat load of up to 280 W (heat flux of 140 W/cm²) was removed by the heat sink with the coolant pressure drop of about 34 kPa across the heat sink system and the heater junction temperature of 62.9 °C at the coolant flow rate of 6.2 cm³/s. Nu number of heat sink increased with the increase of Re number, and maximum value of 323 for Nu was achieved at highest Re of 518. The overall heat transfer coefficient of heat sink increased with the increase of coolant flow rate and heat load, and the maximal heat transfer coefficient was 36.8 kW(m² °C)^?1 in the experiment. The minimum value of 0.16 °C/W for the whole thermal resistance of heat sink was achieved at flow rate of 6.2 cm³/s, and increasing coolant flow rate and heat fluxes could lead to the decrease in thermal resistance. The micro heat sink has good performance for electronics cooling at high heat fluxes, and it can improve the reliability and lifetime of electronic device.     

An asymptotic approach to generalizing the experimental data on convective heat transfer of tube bundles in crossflow

Based on the analysis of experimental data the universal methods of calculating convective heat transfer of smooth and finned tube bundles in the crossflow have been developed over the ranges of geometric characteristics covering all practical needs at the Reynolds number Re = 3 × 10³…1 × 10⁵.The distinctive feature of the methods proposed is that the generalized similarity equation of convective heat transfer takes into account the dependence of the Reynolds number exponent on tube pitch characteristics in a bundle. This has allowed the mechanism of heat transfer and hydraulic performance in tube bundles to be taken into utmost consideration and the asymptotic character to be given to the generalized dependence. In turn, this has permitted one to show the presence of maximum of heat transfer intensity and also to cover limiting combinations of pitches, at which differences in staggered and in-line arrangements of tubes are leveled, i.e., practically the restrictions on the ranges of tube pitch characteristics of bundles can be removed.