Numerical evaluation of additively manufactured lattice architectures for heat sink applications

Abstract

Tailoring the architectural characteristics of lattice materials at different length scales, from nano to macro, has become tenable with emerging advances in additive manufacturing. Cumulative needs of high heat dissipation rates and structural requirements along with lightweight constraints have led to the development of several heat sink fins with lattice architectures in heat exchange-applications. Here, we numerically investigate the potential of polymer-based 3D printed lattice architectures as extended heat transfer surfaces and examine the forcedconvection characteristics of simple-cubic, body-centered-cubic and face-centered-cubic trusses as well as simple-cubic plate, and Kelvin and Octet periodic lattices with mesostructured architecture. All these lattices have a porosity of 77% (relative density ~23%) and surface area density in the range of 1500 − 2400 2 / 3 . Thermal and hydraulic finite element studies were conducted for fluid flow over the lattice architectures for low Reynolds number in the range of 50 − 360 and constant wall temperature conditions. The performance of different celltopologies is characterized in terms of exit fluid temperature, heat transfer coefficient with respect to different reference surface areas, pressure drop per unit length, Colburn factor j, Fanning friction factor f and area goodness factor j/f. The study of the influence of thermal conductivity on heat transfer rate reveals that the polymer-based architected heat sinks perform close to their metallic counterparts when evaluated on per unit mass basis. Furthermore, bodycentered-cubic truss, simple-cubic plate, and Kelvin and Octet lattice-cells were found to exhibit better thermal performance than some microchannel and open-cell foam heat sinks.

Essential work of fracture assessment of acrylonitrile butadiene styrene (ABS) processed via fused filament fabrication additive manufacturing

“…The criteria for damage initiation in the 3Dprinted ABS are based on Hashin's theory [54], which was originally developed for fibre-reinforced composite materials but can also be used for analysis of orthotropic materials [55] by using the definitions of the directions as described in Eqs. (5)(6)(7)(8).…”

“…Additive manufacturing (AM), commonly known as 3D printing, has attracted the interest of the academic and industrial research community because of its ability to fabricate objects with complex geometries at relatively low cost and with high flexibility [1][2][3][4][5][6][7][8][9]. It is an emerging technology where structures are printed layer by layer with the help of computer-aided design (CAD) models.…”

Evaluation of Active Heat Sinks Design under Forced Convection—Effect of Geometric and Boundary Parameters

“…They suggested that Kagome structures have desirable heat-dissipation properties due to the large hexagonal holes through which fluid may flow, compared to triangular and hexagonal cells. More recently, Dixit et al [ 63 ] concluded that octet topology dissipates more heat at the lowest Reynolds numbers while SC-BCC-truss outperforms other architectures as the fluid velocity increases.…”

Thermo-Hydraulic Characteristics of Micro-Scale Surface Roughness Topology of Additively Manufactured Surface Model: Modal Decomposition Perspective

“…In fact, in additive manufacturing, a part is built by layer-by-layer material addition, minimizing the overall waste of raw material [2]. Selective laser sintering, selective laser melting (very similar to selective laser sintering and differing primarily in the materials they use), electron beam melting, and direct metal laser sintering are the additive manufacturing methods dealing with metals [3,4].…”

“…One feature of 3D-printed heat exchanging devices that is important to thermal performance is the minimization of contact thermal resistance caused by conventional attachment of elements on surfaces [4]. Aside from the plus points, the challenges of the additive manufacturing must be considered; overhang printing, removal of supporting structures, compatible raw materials, and minimization of the overall costs can be named as a few [2].…”