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Design of an Improved Heater Array to Measure Microscale Wall Heat Transfer
An improved array of microscale heaters is being developed to measure the heat transfer coefficient at many points underneath individual bubbles during boiling as a function of space and time. This heater array enables the local heat transfer from a surface during the bubble growth and departure process to be measured with very high temporal and spatial resolution, and should allow better understanding of the boiling heat transfer mechanisms by pin-pointing when and where in the bubble departure cycle large amounts of wall heat transfer occur. Such information can provide much needed data regarding the important heat transfer mechanisms during the bubble departure cycle, and can serve as benchmarks to validate many of the analytical and numerical models used to simulate boiling. The improvements to the heater array include using a silicon-on-quartz substrate to reduce thermal cross-talk between the heaters, decreased space between the heaters, increased pad sizes on the heaters, and progressive heater sizes. Some results using the present heater array are discussed.
Prediction of thermal conductivity in dielectrics using fast, spectrally-resolved phonon transport simulations
We present a new method for predicting effective thermal conductivity in materials, informed by ab initio material property simulations. Using the Boltzmann transport equation in a self-adjoint angular flux formulation, we performed simulations in silicon at room temperatures over length scales varying from 10 nm to 10 micron and report temperature distributions, spectral heat flux and thermal conductivity. Our implementation utilizes a Richardson iteration on a modified version of the phonon scattering source. In this method, a closure term is introduced to the transport equation which acts as a redistribution kernel for the total energy bath of the system. This term is an effective indicator of the degree of disorder between the spectral phonon radiance and the angular phonon intensity of the transport system. In conclusion, we employ polarization, density of states and full dispersion spectra to resolve thermal conductivity with numerous angular and spatial discretizations.
Microscale Investigation of Thermo-Fluid Transport in the Transition FIL, Region of an Evaporating Capillary Meniscus Using a Microgravity Environment
In order to enhance the fundamental understanding of thin film evaporation and thereby improve the critical design concept for two-phase heat transfer devices, microscale heat and mass transport is to be investigated for the transition film region using state-of-the-art optical diagnostic techniques. By utilizing a microgravity environment, the length scales of the transition film region can be extended sufficiently, from submicron to micron, to probe and measure the microscale transport fields which are affected by intermolecular forces. Extension of the thin film dimensions under microgravity will be achieved by using a conical evaporator made of a thin silicon substrate under which concentric and individually controlled micro-heaters are vapor-deposited to maintain either a constant surface temperature or a controlled temperature variation. Local heat transfer rates, required to maintain the desired wall temperature boundary condition, will be measured and recorded by the concentric thermoresistance heaters controlled by a Wheatstone bridge circuit, The proposed experiment employs a novel technique to maintain a constant liquid volume and liquid pressure in the capillary region of the evaporating meniscus so as to maintain quasi-stationary conditions during measurements on the transition film region. Alternating use of Fizeau interferometry via white and monochromatic light sources will measure the thin film slope and thickness variation, respectively. Molecular Fluorescence Tracking Velocimetry (MFTV), utilizing caged fluorophores of approximately 10-nm in size as seeding particles, will be used to measure the velocity profiles in the thin film region. An optical sectioning technique using confocal microscopy will allow submicron depthwise resolution for the velocity measurements within the film for thicknesses on the order of a few microns. Digital analysis of the fluorescence image-displacement PDFs, as described in the main proposal, can further enhance the depthwise resolution.
Boiling Heat Transfer Measurements on Highly Conductive Surfaces Using Microscale Heater and Temperature Arrays
Two systems have been developed to study boiling heat transfer on the microscale. The first system utilizes a 32 x 32 array of diodes to measure the local temperature fluctuations during boiling on a silicon wafer heated from below. The second system utilizes an array of 96 microscale heaters each maintained at constant surface temperature using electronic feedback loops. The power required to keep each heater at constant temperature is measured, enabling the local heat transfer coefficient to be determined. Both of these systems as well as some preliminary results are discussed.
High flux boiling heat transfer enhancement using triangle shaped vertical walls in two-phase microchannel heat exchangers
Two-phase heat exchangers allow heat loads to be dissipated with lower fluid flow rates without inducing thermal gradients, and high surface area microchannels further reduce the thermal resistance of these heat exchangers. However, there are many practical limits that prevent widespread use of two-phase microchannel heat exchangers. Many authors have looked to address these practical limits by treating the channel floors or creating artificial nucleation sites. Few works look to enhance heat transfer in the walls of channels with hydraulic diameters below 200 μm. This work is aimed at increasing the efficacy of high aspect ratio silicon microchannels that use R134a as the working fluid. The 125 parallel channels are 40 μm wide, 200 μm deep, and 2 mm long and contain a 15 μm wide, 150 μm long restriction at each inlet. The thermal resistance and dryout characteristics of traditional, plain-walled channels are compared to channels with 2 area enhancement patterns each of which increases the area available for heat transfer by 41%. Furthermore, a resistance to dryout is seen in both area-enhanced test sections, and a 15.5% reduction in thermal resistance is shown for the area-enhanced part with a 6 μm triangular pitch. Only a 7.8% performance increase is seen in the test section with a 3 μm pitch. Both area enhancement patterns induce an average 27% increase in pressure drop for all tests. Heat transfer characteristics are solved for using a finite element analysis (FEA) model. By examining heat transfer coefficients and local heat fluxes, it is postulated that the area enhancement reduces heat transfer coefficients and the performance increase is caused by increasing the number of active nucleation sites.
Microscale Enhancement of Heat and Mass Transfer for Hydrogen Energy Storage
The document summarized the technical progress associated with OSU’s involvement in the Hydrogen Storage Engineering Center of Excellence. OSU focused on the development of microscale enhancement technologies for improving heat and mass transfer in automotive hydrogen storage systems. OSU’s key contributions included the development of an extremely compact microchannel combustion system for discharging hydrogen storage systems and a thermal management system for adsorption based hydrogen storage using microchannel cooling (the Modular Adsorption Tank Insert or MATI).
Special Section on InterPACK 2017—Part 1
InterPACK is a premier international forum for exchange of state-of-the-art knowledge in research, development, manufacturing, and applications of micro-electronics packaging. It is the flagship conference of the ASME Electronic and Photonic Packaging Division (EPPD) founded in 1992 as an ASME-JSME joint biannual conference. Rapid changes in the semiconductor landscape together with findings from InterPACK Pathfinding workshop (IPW) in 2016 led to a significant reset of InterPACK conference priorities and focus to comprehensively address needs of the InterPACK community. As a result, starting in 2017, InterPACK has become an annual conference and the scope of the conference has increased significantly together with a systems-focus to include some of the most cutting-edge topics in electronics packaging, device integration, and reliability. These topics are organized across five different tracks: (1) heterogeneous integration: microsystems with diverse functionality, (2) servers of the future, (3) structural and physical health monitoring, (4) energy conversion and storage, and (5) transportation: autonomous and electric vehicles.
Microscale Modeling of High-Temperature Heat Transfer in Anisotropic Porous Materials
No abstract available
Design, Construction, and Qualification of a Microscale Heater Array for Use in Boiling Heat Transfer
Boiling heat transfer is an efficient means of heat transfer because a large amount of heat can be removed from a surface using a relatively small temperature difference between the surface and the bulk liquid. However, the mechanisms that govern boiling heat transfer are not well understood. Measurements of wall temperature and heat flux near the wall would add to the database of knowledge which is necessary to understand the mechanisms of nucleate boiling. A heater array has been developed which contains 96 heater elements within a 2.5 mm square area. The temperature of each heater element is held constant by an electronic control system similar to a hot-wire anemometer. The voltage that is being applied to each heater element can be measured and digitized using a high-speed A/D converter, and this digital information can be compiled into a series of heat-flux maps. Information for up to 10,000 heat flux maps can be obtained each second. The heater control system, the A/D system and the heater array construction are described in detail. Results are presented which show that this is an effective method of measuring the local heat flux during nucleate and transition boiling. Heat flux maps are obtained for pool boiling in FC-72 on a horizontal surface. Local heat flux variations are shown to be three to six times larger than variations in the spatially averaged heat flux.
Evaluation of the Anisotropic Radiative Conductivity of a Low-Density Carbon Fiber Material from Realistic Microscale Imaging
The radiative heat transfer inside a low-density carbon fiber insulator is analyzed using a three-dimensional direct simulation model. A robust procedure is presented for the numerical calculation of the geometric configuration factor to compute the radiative energy exchange processes among the small discretized surface areas of the fibrous material. The methodology is applied to a polygonal mesh of a fibrous insulator obtained from three-dimensional microscale imaging of the real material. The anisotropic values of the radiative conductivity are calculated for that geometry. The results yield both directional and thermal dependence of the radiative conductivity.
Modular Thermal Hub For Building Cooling, Heating and Water Heating
A thermally activated hub for modular, scalable, distributed cooling and heating in buildings, which uses working fluids with zero Global Warming Potential (GWP), and can run on thermal energy from combustion, low-grade waste heat, or solar energy, was developed and demonstrated in this project. The concept capitalizes on several-fold enhancements in coupled heat and mass transfer possible in microscale passages to remove the primary hurdle that has hindered the implementation of thermally activated heat pumps for more than a century. Cooling capacities of hundreds of watts to tens of kilowatts are possible simply through scaling-up of component geometry. In this project, the proof-of-concept 300 W capacity unit was successfully scaled up to 3.5 kW cooling capacity, and packaged into a compact system. These systems can be utilized for a variety of cooling, heating, and air-conditioning applications in residential and commercial buildings. Additional current and potential market opportunities include CCHP applications (military and private sector mobile power generation, and small residential and light commercial stationary power systems (engine, microturbine and fuel cell driven)), solar cooling applications, distributed process waste heat recovery applications, and long-haul transport refrigeration.
Modular Thermal Hub For Building Cooling, Heating and Water Heating
A thermally activated hub for modular, scalable, distributed cooling and heating in buildings, which uses working fluids with zero Global Warming Potential (GWP), and can run on thermal energy from combustion, low grade waste heat, or solar energy, was developed and demonstrated in this project. The concept capitalizes on several-fold enhancements in coupled heat and mass transfer possible in microscale passages to remove the primary hurdle that has hindered the implementation of thermally activated heat pumps for more than a century. Cooling capacities of hundreds of watts to tens of kilowatts are possible simply through scaling up of component geometry. In this project, the proof-of-concept 300 W capacity unit was successfully scaled up to 3.5 kW cooling capacity, and packaged into a compact system. These systems can be utilized for a variety of cooling, heating, and air-conditioning applications in residential and commercial buildings. Additional current and potential market opportunities include CCHP applications (military and private sector mobile power generation, and small residential and light commercial stationary power systems (engine, microturbine and fuel cell driven)), solar cooling applications, distributed process waste heat recovery applications, and long-haul transport refrigeration.
Numerical Investigation of Susceptor-Catalyst Design for Ethylene Generation in Radio Frequency Based Reactors
Ethylene is the most widely produced petrochemical component in the world. Whether reactors are heated directly or indirectly via steam, manufacturers use economies of scale to overcome inherent thermodynamic inefficiencies when burning fossil fuels. While allowing large-scale operations to use alternative sources of energy and raw materials, new methods of supplying energy to chemical reactor systems can reduce the energy waste produced by conventional processes. One viable method for effectively supplying energy to reactor systems is electromagnetic (EM) induction heating. Using the properties of radio frequency (RF) waves, heterogeneous catalysts can be precisely targeted for heating inside reactors. Site-selective heating can greatly lower the energy requirements of the process by supplying heat to reaction sites while reducing needless heat transfer elsewhere. In this study, a microscale model was used to help create guidelines for susceptors and catalysts to improve ethylene production. The oxidative dehydrogenation of ethane is investigated by utilizing several catalysts and potential catalyst/susceptor combinations, with heat provided by an EM susceptor. Having the susceptors and catalyst function separately results in higher gradients in both heat and mass transfer, which drives transport through the catalyst region, while still providing adequate heating for endothermic reactions. However, using a susceptive core with a catalyst covering produces the maximum ethylene concentration.
Bubble Dynamics, Two-Phase Flow, and Boiling Heat Transfer in Microgravity
This report contains two independent sections. Part one is titled "Terrestrial and Microgravity Pool Boiling Heat Transfer and Critical heat flux phenomenon in an acoustic standing wave." Terrestrial and microgravity pool boiling heat transfer experiments were performed in the presence of a standing acoustic wave from a platinum wire resistance heater using degassed FC-72 Fluorinert liquid. The sound wave was created by driving a half wavelength resonator at a frequency of 10.15 kHz. Microgravity conditions were created using the 2.1 second drop tower on the campus of Washington State University. Burnout of the heater wire, often encountered with heat flux controlled systems, was avoided by using a constant temperature controller to regulate the heater wire temperature. The amplitude of the acoustic standing wave was increased from 28 kPa to over 70 kPa and these pressure measurements were made using a hydrophone fabricated with a small piezoelectric ceramic. Cavitation incurred during experiments at higher acoustic amplitudes contributed to the vapor bubble dynamics and heat transfer. The heater wire was positioned at three different locations within the acoustic field: the acoustic node, antinode, and halfway between these locations. Complete boiling curves are presented to show how the applied acoustic field enhanced boiling heat transfer and increased critical heat flux in microgravity and terrestrial environments. Video images provide information on the interaction between the vapor bubbles and the acoustic field. Part two is titled, "Design and qualification of a microscale heater array for use in boiling heat transfer." This part is summarized herein. Boiling heat transfer is an efficient means of heat transfer because a large amount of heat can be removed from a surface using a relatively small temperature difference between the surface and the bulk liquid. However, the mechanisms that govern boiling heat transfer are not well understood. Measurements of wall temperature and heat flux near the wall would add to the database of knowledge which is necessary to understand the mechanisms of nucleate boiling. A heater array has been developed which contains 96 heater elements within a 2.5 mm square area. The temperature of each heater element is held constant by an electronic control system similar to a hot-wire anemometer. The voltage that is being applied to each heater element can be measured and digitized using a high-speed Analog to Digital (A/D) converter, and this digital information can be compiled into a series of heat-flux maps. Information for up to 10,000 heat flux maps can be obtained each second. The heater control system, the A/D system and the heater array construction are described in detail. Results are presented which show that this is an effective method of measuring the local heat flux during nucleate and transition boiling. Heat flux maps are obtained for pool boiling in FC-72 on a horizontal surface. Local heat flux variations are shown to be three to six times larger than variations in the spatially averaged heat flux.
Diesel Engine Waste Heat Driven Absorption Heat Pumps for ECU Applications in Defense Installations
A thermally activated absorption heat pump suitable for use in naval expeditionary Environmental Control Units, as well as residential space-conditioning, is developed. Waste heat characteristic of the exhaust stream from a diesel engine GenSet is used to drive an absorption cycle to provide cooling. The heat source is coupled to the heat pump using an intermediate fluid loop for flexible deployment. With minor modifications, the heat pump could also provide heating at high coefficients of performance, resulting in versatile functionality. This technology capitalizes on heat and mass transfer enhancement possible in microscale passages to provide a compact architecture for the components and the overall system. The working fluid pair with zero Global Warming Potential is contained within this assembly, reducing fluid inventories significantly over conventional systems. Quiet, reliable, long-life operation due to the absence of a compressor and the use of few moving parts are further critical distinguishing advantages. Modularity in cooling capacity has been demonstrated through scaling-up of component geometry and internal features and dimensions. The core technology was initially demonstrated with a proof-of-concept microscale absorption chiller measuring 200 × 200 × 34 mm and weighing 7 kg that delivered 300 W of cooling in laboratory tests. In the previous BEETIT project, the team made significant advances over the proof-of-concept. System and component designs with > 10× scale-up in capacity were developed, in a packaged unit capable of standalone operation with a semi-autonomous control system. A cooling capacity of 3.5 kW with a COP > 0.5 at an ambient temperature of 35°C was demonstrated for this natural gas-fired unit. Significant cost reductions in fabrication were achieved using low-cost brazing instead of diffusion bonding. In companion projects funded by the Southern Company and the Georgia Research Alliance, stamping and fluid forming techniques were investigated to fabricate microscale features instead of photochemical etching, thereby leading to significant cost reductions. In a follow-on effort funded by ARPA-E and NAVFAC, a 2.7 kW cooling unit was developed to provide cooling at a severe ambient condition of 51.7°C. The unit was driven directly by diesel engine exhaust heat. Innovative finned heat and mass exchangers for the ambient-coupled condenser and absorber were developed. In the present effort, a standalone, packaged and controllable 10.5 kW cooling capacity absorption chiller is developed. This demonstrates a 30× scale up from the proof-of-concept, thus validating the scalability of microchannel heat exchangers for absorption heat pumps. Autonomous operation algorithms demonstrated enhanced dynamic performance. The knowledge from previous projects was leveraged to develop novel component designs that further helped in miniaturizing the heat exchangers. All coupling fluids are hydronically coupled to aid flexible field deployment. The prototype unit provides design cooling capacity at high ambient temperature conditions of 44°C at COP > 0.6.
Subcooled Pool Boiling Heat Transfer Mechanisms in Microgravity: Terrier-improved Orion Sounding Rocket Experiment
A microscale heater array was used to study boiling in earth gravity and microgravity. The heater array consisted of 96 serpentine heaters on a quartz substrate. Each heater was 0.27 square millimeters. Electronic feedback loops kept each heater's temperature at a specified value. The University of Maryland constructed an experiment for the Terrier-Improved Orion sounding rocket that was delivered to NASA Wallops and flown. About 200 s of high quality microgravity and heat transfer data were obtained. The VCR malfunctioned, and no video was acquired. Subsequently, the test package was redesigned to fly on the KC-135 to obtain both data and video. The pressure was held at atmospheric pressure and the bulk temperature was about 20 C. The wall temperature was varied from 85 to 65 C. Results show that gravity has little effect on boiling heat transfer at wall superheats below 25 C, despite vast differences in bubble behavior between gravity levels. In microgravity, a large primary bubble was surrounded by smaller bubbles, which eventually merged with the primary bubble. This bubble was formed by smaller bubbles coalescing, but had a constant size for a given superheat, indicating a balance between evaporation at the base and condensation on the cap. Most of the heaters under the bubble indicated low heat transfer, suggesting dryout at those heaters. High heat transfer occurred at the contact line surrounding the primary bubble. Marangoni convection formed a "jet" of fluid into the bulk fluid that forced the bubble onto the heater.