Freeze‐casting is a technique used to produce structures with anisotropic porosity in the form of well‐defined microchannels throughout a sample. Here, this technique is used on the magnetocaloric ceramic La0.66Ca0.26Sr0.07 Mn1.05O3. We show that a dynamic freezing profile, where the temperature is decreased continuously at −10 K/min, results in homogeneous, lamellar channels with widths of ∼15 µm, while static freezing, where the temperature is kept constant at 177 K, results in channels of increasing size away from the initial ice crystal nucleation site. The effect of gelation before freeze‐casting is also investigated. Gelation inhibits ice crystal growth, which significantly changes the morphology by making channel cross sections less elongated, while additionally introducing more dendrites and ceramic bridges in the structure. The latter significantly dominates the flow path through the gelated structures, affecting the calculated tortuosity, which increases to τ ≈ 4 when compared to non‐gelated samples where calculated tortuosities are in the range of ∼1.3 to ∼3. Finally, we present a systematic and automatic approach for evaluating channel and wall sizes and calculating tortuosities. This is based on analysis of images obtained by scanning electron microscopy using a continuous particle size distribution method and the TauFactor application in MATLAB®.
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The efficiency of the magnetic refrigeration process strongly depends on the heat transfer performance of the regenerator. As a potential way to improve the heat transfer performance of a regenerator, the design of sub-millimeter hydraulic diameter porous structures is realized by freeze-cast structures. Four freeze-cast regenerators with different pore widths are characterized experimentally and numerically. Empirical parameters are determined for the correlations of heat transfer and flow resistance via a 1D model. Thermal effectiveness and pressure drop are measured for thermal-hydraulic evaluations. Temperature span and specific cooling capacity are obtained to compare the magnetocaloric potential based on the material La0.66Ca0.27Sr0.06Mn1.05O3. The stability of freeze-cast regenerators is validated by comparing the performance during, before and after oscillatory flow and periodic magnetic field tests. Smaller pore design obtain the better heat transfer performance and required mechanical strength, while pore design with significant dendrites provides the worst tradeoff between heat transfer performance and flow resistance.
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