Influence of Alumina Addition to Aluminum Fins for Compact Heat Exchangers Produced by Cold Spray Additive Manufacturing

Farjam, Aslan; Cormier, Yannick; Dupuis, Philippe; Jodoin, B.; Corbeil, Antoine

doi:10.1007/s11666-015-0305-4

Cited by 22 publications

(4 citation statements)

References 65 publications

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“…These values were lower than those of the fractions in the corresponding feedstock powders. In the cold-spray process, the metal-ceramic coating normally shows a decreased ceramic content compared to the initial feedstock, indicating that the deposition efficiency of ceramic particles is lower than that of the soft particles [29,35,36]. Aluminium is a particularly interesting cold-spray candidate material because it can be accelerated to very high velocities owing to its low density [37].…”

Section: Resultsmentioning

confidence: 99%

Effect of reinforcement particles on cold-sprayed Al-based coatings

Li¹,

Wu²,

Ding³

et al. 2021

Surface Engineering

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In this study, malleable and heavy Ta particles were introduced into soft Al powders to prepare Al-Ta composite coatings through a low-pressure cold-spray process; for comparison, Al-A 2 O 3 composite coatings were also deposited. The surface and cross-sectional morphologies, deposition efficiency, microstructure, hardness and composition of the coatings were investigated. The results demonstrated that the Al-Ta coatings had roughness values that were almost twice as large as those of the Al-Al 2 O 3 coatings for the same volumetric fraction of reinforcement particles used in the feedstock. Ta particles were more effective in improving the deposition efficiency and densification than were Al 2 O 3 particles. The formation mechanism of the Al-Ta coatings was mainly attributed to the malleable and heavy nature of Ta particles, which allowed them to bond with the formed coating and impact the coating strongly through the peening effect.

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Section: Resultsmentioning

confidence: 99%

Effect of reinforcement particles on cold-sprayed Al-based coatings

Li¹,

Wu²,

Ding³

et al. 2021

Surface Engineering

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“…-The use of aluminum-alumina powder as an alternative to pure aluminum eliminates the need for expensive polymer nozzles that wear out quickly. [175] -Produces near-net-shape pyramidal fin arrays in a variety of materials, including aluminum, nickel and Class 34 stainless steel.…”

Section: Heat Exchangers Using 3d Printing Technologymentioning

confidence: 99%

Potential of 3D Printing for Heat Exchanger Heat Transfer Optimization—Sustainability Perspective

Anwajler

2024

Inventions

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In just a few short years, the additive manufacturing (AM) technology known as 3D printing has experienced intense growth from a niche technology to a disruptive innovation that has captured the imagination of mainstream manufacturers and hobbyists alike. The purpose of this article is to introduce the use of 3D printing for specific applications, materials, and manufacturing processes that help to optimize heat transfer in heat exchangers, with an emphasis on sustainability. The ability to create complex geometries, customize designs, and use advanced materials provides opportunities for more efficient and stable heat transfer solutions. One of the key benefits of incremental technology is the potential reduction in material waste compared to traditional manufacturing methods. By optimizing the design and structure of heat transfer components, 3D printing enables lighter yet more efficient solutions and systems. The localized manufacturing of components, which reduces the need for intensive transportation and associated carbon emissions, can lead to reduced energy consumption and improved overall efficiency. The customization and flexibility of 3D printing enables the integration of heat transfer components into renewable energy systems. This article presents the key challenges to be addressed and the fundamental research needed to realize the full potential of incremental manufacturing technologies to optimize heat transfer in heat exchangers. It also presents a critical discussion and outlook for solving global energy challenges through innovative incremental manufacturing technologies in the heat exchanger sector.

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“…In a study performed by Cormier et al [58], cold spray technology (additive manufacturing) was used to fabricate pyramidal pin heat sinks from Al6061 alloy with a maximum attainable height of ~ 2.5 mm at aspect ratios up to 4, but the fin density was limited to 24 pins per inch. Farjam et al [59] used aluminum-alumina powder mixtures to produce fin arrays via cold spray because they found that using this powder instead of pure aluminum was more costeffective, although it still negatively affected the heat transfer performance. Besides the limitation on the fabrication of high aspect ratio structures, pin geometries made using the cold spray technique are not of uniform dimensions due to the physics of the process, and the random adhesion of particles during spraying [59].…”

Section: Introductionmentioning

confidence: 99%

“…Farjam et al [59] used aluminum-alumina powder mixtures to produce fin arrays via cold spray because they found that using this powder instead of pure aluminum was more costeffective, although it still negatively affected the heat transfer performance. Besides the limitation on the fabrication of high aspect ratio structures, pin geometries made using the cold spray technique are not of uniform dimensions due to the physics of the process, and the random adhesion of particles during spraying [59]. Primeaux et al [60] studied the manufacturing of fin array structures as heat sinks using sheet metal roll molding of pure aluminum and Al6061 alloy sheets.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

Azarsa¹

2023

Preprint

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Many advanced engineering materials are machined using abrasive water jets, a non-traditional machining method that has certain advantages compared to other approaches. This dissertation aims at developing methodologies to use abrasive water and slurry jets to micro-machine free-standing structures for heat sink and microfluidics applications. The first aim was to fabricate high aspect ratio free-standing structures with a minimum distance between each other that would lead to maximum heat transfer performance in heat sinks. The effect of machining process parameters on the quality of the resulting free-standing structures was studied. It was demonstrated that high-quality free-standing structures with aspect ratios of more than 40 to be used as fins in heat sinks could be fabricated. There is an increasing demand for metallic micro-molds that can be used for inexpensive mass production of polymeric microfluidic chips. Therefore, the feasibility of using abrasive water jet micro-machining (AWJM) and abrasive slurry jet micro-machining (ASJM) to fabricate such micro-molds was studied. Jet raster scans under various combinations of process parameters were used in order to machine micro-pockets containing free-standing structures, representing molds for casting microfluidic chips with channel networks. The optimum process parameters and material were determined in order to fabricate the molds with the best possible surface finish. Because unmasked machining could not be used to fabricate molds with sharp-edged intersecting features, a hybrid AWJM/ASJM masked machining technique was introduced. By careful selection of the process parameters, high quality molds with both single and intersecting free-standing structures at multiple heights could be fabricated, thus making three-dimensional microfluidic chip mold fabrication feasible. Finally, a new method of mold fabrication that utilized water jet cutting technology to cut free-standing structures out of mild steel sheets, to be used as a mold for PDMS casting, was developed. This enabled 3D features having very abrupt changes in depth with almost 90o angles for use in microfluidic devices. As a proof-of-concept, a polydimethylsiloxane (PDMS) chip was made and tested. It was shown that this alternative approach to create microfluidic molds is versatile and may find utility in reducing the cost and complexity involved in fabricating 3D features in microfluidic devices.

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Influence of Alumina Addition to Aluminum Fins for Compact Heat Exchangers Produced by Cold Spray Additive Manufacturing

Cited by 22 publications

References 65 publications

Effect of reinforcement particles on cold-sprayed Al-based coatings

Effect of reinforcement particles on cold-sprayed Al-based coatings

Potential of 3D Printing for Heat Exchanger Heat Transfer Optimization—Sustainability Perspective

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

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