In this paper, an experimental program and a CFD based mathematical model using a brush seal at two bristle to rotor clearances (0.27 mm and 0.75 mm) are presented. The experimental program examined the radial pressure distributions along the backing ring, the axial pressure distribution along the rotor, and the mass flow through the seal through a range of pressure ratios while exhausting to atmosphere. The results from this experimental program have been used to further calibrate a CFD-based model. This model treats the bristle pack as an axisymmetric, anisotropic porous region, and is calibrated by the definition of nonlinear resistance coefficients in three orthogonal directions. The CFD analysis calculates the aerodynamic forces on the bristles, which are subsequently used in a separate program to estimate the bristle movements, stresses, and bristle and rotor loads. The analysis shows that a brush seal with a build clearance produces a very different flow field within the bristle pack to one with an interference, and the need to understand the bulk movements of the bristles. These are shown to be affected by the level of friction between the bristles and the backing ring, which has an important effect on the bristles wear and seal leakage characteristics.

The evaporative cooling system concepts proposed over the past century for engine thermal management in automotive applications are examined and critically reviewed. The purposes of this review are to establish the evident system shortcomings and to identify the remaining research questions that need to be addressed to enable this important technology to be adopted by vehicle manufacturers. Initially, the benefits of the evaporative cooling systems are restated in terms of the improved engine efficiency, the reduced carbon dioxide emissions and the improved fuel economy. This is followed by a historical coverage of the proposed concepts dating back to 1918. Possible evaporative cooling concepts are then classified into four distinct classes and critically reviewed. This culminates in an assessment of the available evidence to establish the reasons why no system has yet been approved for serial production commercially. Then, by systematic examination of the critical areas in evaporative cooling systems for application to automotive engine cooling, the remaining research challenges are identified

New empirical correlation models are constructed to characterise heat transfer associated with spray evaporative cooling of vibrating surfaces -a process involving complex two-phase physics well beyond current numerical simulation capabilities. The proposed correlation models, which account for dynamic, rather than just static surface conditions as in existing models, are constructed using dimensional analysis involving the Generalized Buckingham Π-Theorem. Experimentally-measured spray evaporative cooling data is used to fit the model using the Vibrational Reynolds number and a dimensionless acceleration number which better correlate the influence of surface frequency and amplitude in the nucleate boiling regime. Different coolant flow-rates through a full-cone spray nozzle are used to cool a flat circular test-piece acting as a horizontal surface. The test-piece surface is excited by a shaker through a range of low and high vibration frequencies and amplitudes. The results show that surface dynamic effects certainly influence nucleate boiling, but they also show that surface vibration does not have the same effect for all excess temperatures -dynamic effects can either increase or decrease heat transfer depending on the heat transfer mechanism. These new models are important for thermal management in several areas, particularly involving batteries, power electronics, and electrical machines in automotive and aerospace applications.

A relatively simple theory is presented that can be used to model the flow and pressure distribution in a brush seal matrix. The model assumes laminar, compressible, isothermal flow and requires knowledge of an empirical constant: the seal porosity value. Measurements of the mass flow rate together with radial and axial distributions of pressure were taken on a nonrotating experimental rig. These were obtained using a 122 mm bore brush seal with 0.25 mm radial interference. The experimental data are used to estimate the seal porosity. Measurements of the pressure distributions along the backing ring and under the bristle tips and discussed. Predicted mass flows are compared with those actually measured and there is reasonable agreement considering the limitations of the model.

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