Novel Stacked Wire Mesh Compact Heat Exchangers Produced Using Cold Spray

Abstract

This study examines the feasibility of using the pulsed gas dynamic spraying (PGDS) process to deposit metal powder on the outer surfaces of metal wire mesh wafers for use as high-performance compact heat exchangers. Plain-square weave woven mesh produced from stainless steel wires were stacked and sintered to form wire mesh bricks, which were then cut into wafers. The outer surfaces of the wafers were sealed using the PGDS deposition technique as opposed to the more traditional brazing sheet solution. This approach provides more intimate contact between the mesh wire tips and sealed surface, thereby promoting conduction through the outer walls and improving the heat exchanger efficiency. In addition, PGDS is an attractive alternative to brazing sheets for this application because of its potential for reduced manufacturing costs. Burst and tensile tests of the PGDS coated wafers were carried out.

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

“…These issues include the limitation in the number of times that the meshes can be folded, the small connection area between wire meshes and the separating plates, high energy consumption and large costs to produce the heat exchanger. A novel solution for the aforementioned problems has been developed with the assistance cold of spray [23]. This method utilizes metallic woven wire mesh sheets which are cut and stacked on each other like matrices and instead of brazing the tips of the wires to the parting plates, thermal spray processes such as cold spray are used to seal them [23].…”

“…A novel solution for the aforementioned problems has been developed with the assistance cold of spray [23]. This method utilizes metallic woven wire mesh sheets which are cut and stacked on each other like matrices and instead of brazing the tips of the wires to the parting plates, thermal spray processes such as cold spray are used to seal them [23]. In order to improve the efficiency of the WMHE, fins can be added to the top and the bottom of the separating plates.…”

“…A significant amount of work has been performed on WMHE as well as the production of pyramidal pin fins produced by additive manufacturing cold spray process [7][8][9], [23], [25], [60][61][62]. The thermal performance enhancement of heat exchanger surfaces by additive manufacturing of fins using the cold spray technique (as illustrated in Figure 2.17) is an innovative idea for which limited investigation work has been done.…”