Flow structure identification and analysis in fin arrays produced by cold spray additive manufacturing

Dupuis, Philippe; Cormier, Yannick; Fenech, Marianne; Corbeil, Antoine; Jodoin, B.

doi:10.1016/j.ijheatmasstransfer.2015.10.019

Cited by 25 publications

(7 citation statements)

References 26 publications

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“…The additive manufacturing process yields extremely rough surfaces [17], a consequence of the sintering process. One group of studies led by Jodoin [18][19][20] examined arrays of aluminum pyramidal pin fins that were manufactured additively via Cold Gas Dynamic Spraying. The authors collected bulk heat transfer data and reported good thermal performance coupled with high pressure losses.…”

Section: Literature Reviewmentioning

confidence: 99%

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Pressure loss and heat transfer performance for additively and conventionally manufactured pin fin arrays

Kirsch

Thole

2017

International Journal of Heat and Mass Transfer

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Pin fin heat exchangers represent a common, viable means of keeping components cool and are widely used for electronics cooling and turbine airfoil cooling. Advancements in manufacturing technology will allow these heat exchangers to be built using new methods, such as laser powder bed fusion, a form of additive manufacturing. New manufacturing approaches, however, render a direct comparison between newly and conventionally manufactured parts meaningless without a good understanding of the difference in the performance. This research study investigated microchannel pin fin arrays that were manufactured using Laser Powder Bed Fusion and compared them to studies of pin fin arrays from the literature, which are representative of traditionallymanufactured pin fin arrays, where the pin and endwall surfaces exhibited much lower surface roughness. Pin fin arrays with four different spacings were manufactured and tested over a range of Reynolds numbers; pressure loss and heat transfer measurements were taken. Additionally, the test coupons were evaluated nondestructively and the asbuilt geometric features were analyzed. Measured surface roughness was found to be extremely high in each one of the microchannel pin fin arrays and was found to be a function of the pin spacing in the array, as was the shape of the pin itself; with more pins in the array came higher surface roughness and more distorted pin shapes. Comparisons between the smooth pin fin arrays from literature and the rough pin fin arrays from the current study showed that the high surface roughness more strongly affected the friction factor augmentation than it did the heat transfer augmentation relative to the smooth pin fin arrays.

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Section: Literature Reviewmentioning

confidence: 99%

“…The authors collected bulk heat transfer data and reported good thermal performance coupled with high pressure losses. The authors also performed μ-Particle Image Velocimetry (μPIV) measurements and saw turbulence intensities of up to 25% at ReDh=500 [20]; the high surface roughness caused an early transition to turbulence.…”

Section: Literature Reviewmentioning

confidence: 99%

Pressure loss and heat transfer performance for additively and conventionally manufactured pin fin arrays

Kirsch

Thole

2017

International Journal of Heat and Mass Transfer

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“…In subsequent works by Cormier et al [60,61] and Dupuis et al, [60,61] the use of cold spraying in energy applications, specifically for efficient heat transfer, was also demonstrated (see Section 3.1.2). The coating materials used in these studies were tens of microns in size, and the technique was inapplicable to the fabrication of ultrathin materials (Tables 1 and 2).…”

Section: 1)]mentioning

confidence: 96%

“…Section 2.1). [60,61] To deposit and form the pyramidal Cu fin arrays, steel wire mesh was used under the optimized cold spraying conditions ( Figure 20a). The flow structures over the Cu fin arrays were predicted using FLUENT.…”

Section: Section 23)mentioning

confidence: 99%

Supersonic Cold Spraying for Energy and Environmental Applications: One‐Step Scalable Coating Technology for Advanced Micro‐ and Nanotextured Materials

Joshi

Yarin

et al. 2019

Advanced Materials

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Supersonic cold spraying is an emerging technique for rapid deposition of films of materials including micron-size and submicron metal particles, nanoscale ceramic particles, clays, polymers, hybrid materials comprised of polymers and particulates, reduced graphene oxide (rGO), and metal-organic frameworks. In this method, particles are accelerated to a high velocity and then impact a substrate at near ambient temperature, where dissipation of their kinetic energy produces strong adhesion. This manuscript reviews the recent progress in fundamentals and applications of cold spraying. High velocity impact with the substrate results in significant deformation, which not only produces adhesion, but can change the particles' internal structure. Cold-sprayed coatings can also exhibit micro-and nanotextured morphologies not achievable by other means. Suspending micro-or nanoparticles in a liquid and cold-spraying the suspension produces fine atomization and even deposition of materials that could not otherwise be processed. The scalability and low-cost of this method and its This article is protected by copyright. All rights reserved. 3 compatibility with roll-to-roll processing make it promising for many applications, including ultra-thin flexible materials, solar cells, touch-screen panels, nanotextured surfaces for enhanced heat transfer, thermal and electrical insulation films, transparent conductive films, materials for energy storage (e.g. Li-ion battery electrodes), heaters, sensors, photoelectrodes for water splitting, water purification membranes, and self-cleaning films.

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“…Jodoin and associates [19][20][21] used cold spray additive manufacturing to build pin fin arrays containing pyramidal pin fins. lparticle image velocimetry measurements showed that the high surface roughness, a consequence of the manufacturing process, caused an early transition to turbulence; turbulence intensities were quoted up to 25% for a Reynolds number of 500 [20]. Dede et al [22] applied the selective laser melting technique to build a finned external flow heat exchanger and found the roughness to be beneficial to the heat transfer.…”

Section: Literature Reviewmentioning

confidence: 99%

Effects of Geometry, Spacing, and Number of Pin Fins in Additively Manufactured Microchannel Pin Fin Arrays

Ferster

Kirsch

Thole

2017

Journal of Turbomachinery

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The demand for higher efficiency is ever present in the gas turbine field and can be achieved through many different approaches. While additively manufactured parts have only recently been introduced into the hot section of a gas turbine engine, the manufacturing technology shows promise for more widespread implementation since the process allows a designer to push the limits on capabilities of traditional machining and potentially impact turbine efficiencies. Pin fins are conventionally used in turbine airfoils to remove heat from locations in which high thermal and mechanical stresses are present. This study employs the benefits of additive manufacturing to make uniquely shaped pin fins, with the goal of increased performance over conventional cylindrical pin fin arrays. Triangular, star, and spherical shaped pin fins placed in microchannel test coupons were manufactured using direct metal laser sintering (DMLS). These coupons were experimentally investigated for pressure loss and heat transfer at a range of Reynolds numbers. Spacing, number of pin fins in the array, and pin fin geometry were variables that changed pressure loss and heat transfer in this study. Results indicate that the additively manufactured triangles and cylinders outperform conventional pin fin arrays, while stars and dimpled spheres did not.

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Flow structure identification and analysis in fin arrays produced by cold spray additive manufacturing

Cited by 25 publications

References 26 publications

Pressure loss and heat transfer performance for additively and conventionally manufactured pin fin arrays

Pressure loss and heat transfer performance for additively and conventionally manufactured pin fin arrays

Supersonic Cold Spraying for Energy and Environmental Applications: One‐Step Scalable Coating Technology for Advanced Micro‐ and Nanotextured Materials

Effects of Geometry, Spacing, and Number of Pin Fins in Additively Manufactured Microchannel Pin Fin Arrays

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