Conjugate Heat Transfer Analysis of an Ultrasonic Molten Metal Treatment System

In piezoceramic ultrasonic devices,the piezoceramic stacks may fail permanently or function improperly if their working temperatures overstep the Curie temperature of the piezoceramic material.While the end of the horn usually serves near the melting point of the molten metal and is enclosed in an airtight chamber,so that it is difficult to experimentally measure the temperature of the transducer and its variation with time,which bring heavy difficulty to the design of the ultrasonic molten metal treatment system.To find a way out,conjugate heat transfer analysis of an ultrasonic molten metal treatment system is performed with coupled fluid and heat transfer finite element method.In modeling of the system,the RNG model and the SIMPLE algorithm are adopted for turbulence and nonlinear coupling between the momentum equation and the energy equation.Forced air cooling as well as natural air cooling is analyzed to compare the difference of temperature evolution.Numerical results show that,after about 350 s of working time,temperatures in the surface of the ceramic stacks in forced air cooling drop about 7 K compared with that in natural cooling.At 240 s,The molten metal surface emits heat radiation with a maximum rate of about 19 036 W/m2,while the heat insulation disc absorbs heat radiation at a maximum rate of about 7922 W/m2,which indicates the effectiveness of heat insulation of the asbestos pad.Transient heat transfer film coefficient and its distribution,which are difficult to be measured experimentally are also obtained through numerical simulation.At 240 s,the heat transfer film coefficient in the surface of the transducer ranges from–17.86 to 20.17 W/（m2？K）.Compared with the trial and error method based on the test,the proposed research provides a more effective way in the design and analysis of the temperature control of the molten metal treatment system.

Streamline upwind finite element method for conjugate heat transfer problems

This paper presents a combined finite element method for solving conjugate heat transfer problems where heat conduction in a solid is coupled with heat convection in viscous fluid flow. The streamline upwind finite element method is used for the analysis of thermal viscous flow in the fluid region, whereas the analysis of heat conduction in solid region is performed by the Galerkin method. The method uses the three-node triangular element with equal-order interpolation functions for all the variables of the velocity components, the pressure and the temperature. The main advantage of the proposed method is to consistently couple heat transfer along the fluid-solid interface. Three test cases, i.e. conjugate Couette flow problem in parallel plate channel, counter-flow in heat exchanger, and conjugate natural convection in a square cavity with a conducting wall, are selected to evaluate the efficiency of the present method.

Numerical Simulation and Control of Two-Phase Flow with Evaporation in a Vertical Tube Submitted to a Conjugate Heat Transfer

A better understanding of two-phase flows with evaporation allows leading to an optimal design of evaporators. For that purpose, numerical simulations are very useful. In this paper, a numerical study has been carried out in order to model and simulate the combination of a two-phase flow with evaporation in a vertical tube. The VOF （volume-of-fluid） multiphase flow method and a phase-change model for the mass transfer have been used. For an accurate modeling, the effect of axial conduction has been also taken into account using a conjugate heat transfer model. Since thermal oscillations are undesirable as they can lead to the failure of the tube, flow instabilities have also been analyzed, using FFT （fast Fourier transforms）, in order to comprehend their behavior and influence. A control study of the flow instabilities in the tube is also presented. For that purpose tube inlet temperature has been varied using a gain control parameter.

Numerical simulation on conjugate heat transfer of turbine cascade

Numerical simulation on conjugate heat transfer of an internal cooled turbine vane was carried out. Numerical techniques employed included the third-order accuracy TVD scheme, multi-block structured grids and the technique of arbitrary curved mesh. Comparison between results of commercial CFD codes with several turbulence models and those of this code shows that it is incorrect of commercial CFD codes to predict the thermal boundary layer with traditional turbulence models, and that turbulence models considering transition lead to more accurate heat transfer in thermal boundary layer with some reliability and deficiency yet. The results of this code are close to those of CFX with transition model.

Investigation of convection cooling guide vane with conjugate heat transfer method

This paper studied a certain blade with ten radial cooling holes which employed conjugate heat transfer method. The cooling air entered the cooling channel from the bottom of the blade and went out from the top, it was not ejected into the main flow. This paper used different numerical conditions including different turbulence models,turbulence intensities,thermal conduction coefficients and the influence on fluid property via temperature variation. The temperature distribution and pressure distribution of the blade were compared with experimental data. The results show that the numerical results using different turbulence models are almost identical to experimental data even little deviation occurs at shock wave location. The trends of temperature distribution under different numerical conditions are coincident to experimental data,especially Reynolds stress turbulence model. It can be concluded that anisotropic turbulence models can simulate the transition from laminar to turbulence,and the influence of turbulence intensity on laminar region and transition region is more than that on developed turbulent region.

A new algorithm of global tightly-coupled transient heat transfer based on quasi-steady flow to the conjugate heat transfer problem

Concerning the specific demand on solving the long-term conjugate heat transfer （CHT） problem, a new algorithm of the global tightly-coupled transient heat transfer based on the quasi-steady flow field is further put forward. Compared to the traditional loosely-coupled algorithm, the computational efficiency is further improved with the greatly reduced update frequency of the flow field, and moreover the update step of the flow field can be reasonably determined by using the engineering empirical formula of the Nusselt number based on the changes of the inlet and outlet boundary conditions. Taking a duct heated by inner forced air flow heating process as an example, the comparing results to the tightly-coupled transient calculation by Fluent software shows that the new algorithm can significantly improve the computational efficiency with a reasonable accuracy on the transient temperature distribution, such as the computing time is reduced to 22,8% and 40% while the duct wall temperature deviation are 7% and 5% respectively using two flow update time step of 100 s and 50 s on the variable inlet-flow rate conditions.

Numerical Study of Conjugate Heat Transfer for Cooling the Circuit Board

In this paper, a 3D model of a flat circuit board with a heat generating electronic chip mounted on it has been studied numerically. The conjugate heat transfer including the conduction in the chip and convection with the surrounding fluid has been investigated numerically. Computational fluid dynamics using the finite volume method has been used for modeling the conjugate heat transfer through the chip and the circuit board. Conjugate heat transfer has broad applications in engineering and industrial applications in design of cooling off electronic components. Effects of various inlet velocities have been studied on the heat transfer variation and temperature of the circuit board. Numerical results show that the temperature of the chip reduces as the velocity of the inlet fluid flow increases.

Calculation of Mass Concrete Temperature and Creep Stress under the Influence of Local Air Heat Transfer

Temperature-induced cracking during the construction of mass concrete is a significant concern.Numerical simulations of concrete temperature have primarily assumed that the concrete is placed in an open environment.The problem of heat transfer between the air and concrete has been simplified to the concrete’s heat dissipation boundary.However,in the case of tubular concrete structures,where air inlet and outlet are relatively limited,the internal air temperature does not dissipate promptly to the external environment as it rises.To accurately simulate the temperature and creep stress in tubular concrete structures with enclosed air spaces during construction,we establish an air–concrete coupled heat transfer model according to the principles of conjugate heat transfer,and the accuracy of the model is verified through experiments.Furthermore,we conduct a case study to analyze the impact of airflow within the ship lock corridor on concrete temperature and creep stress.The results demonstrate that enhancing airflow within the corridor can significantly reduce the maximum concrete temperature.Compared with cases in which airflow within the corridor is neglected,the maximum concrete temperature and maximum tensile stress can be reduced by 12.5℃ and 0.7 MPa,respectively,under a wind speed of 4 m/s.The results of the traditional calculation method are relatively close to those obtained at a wind speed of 1 m/s.However,the temperature reduction process in the traditional method is faster,and the method yields greater tensile stress values for the corridor location.

A Finite Volume Method Preserving Maximum Principle for the Conjugate Heat Transfer Problems with General Interface Conditions

In this paper,we present a unified finite volume method preserving discrete maximum principle(DMP)for the conjugate heat transfer problems with general interface conditions.We prove the existence of the numerical solution and the DMP-preserving property.Numerical experiments show that the nonlinear iteration numbers of the scheme in[24]increase rapidly when the interfacial coefficients decrease to zero.In contrast,the nonlinear iteration numbers of the unified scheme do not increase when the interfacial coefficients decrease to zero,which reveals that the unified scheme is more robust than the scheme in[24].The accuracy and DMP-preserving property of the scheme are also veri ed in the numerical experiments.

Conjugate Heat Transfer Analysis of Film Cooling Flows

The objective of this study is to evaluate the potential of various grids to satisfactorily simulate the development of a cooling film, using a coupled computation that takes into account the full geometry. Detailed computations of a single row of 30 degrees round holes on a flat plate are presented for blowing ratios of 0.764, 1.01 and 1.54. The simulation results are compared well with experimental data. The two-layer model gave more accurate results but consumed much more computational time than the standard wall functions. The k-ε turbulence model with wall functions with appropriate values of y^＋ is suitable for practical use. The results show the importance of the conjugate calculation for accurately describing the influence of the heat transfer within the cooling film.

Retrofit design of composite cooling structure of a turbine blade by fluid networks and conjugate heat transfer methods

This article discusses the development of the numerical methods of gas flow coupled with heat transfer,and introduces the fluid net-works method for rapid prediction of the performance of the composite cooling structures in turbine blade.The reliability of these methods is verified by comparing experimental data.For a HPT rotor blade,a rapid prediction on the internal cooling structures is first made by using the fluid network analysis,then an assessment of aerodynamic and heat transfer characteristics is conducted.Based on the network analysis results,three ways to improve the design of the cooling structures are tested,i.e.,adjusting the cooling gas flow mass ratios for different inner cooling cavities,reducing the flow resistances of the channel turning structures,and improving the local internal cooling structure geometries with high temperature distribution.Through the verification of full three-dimensional gas/solid/coolant conjugate heat transfer calculation,we conclude that the modified design can make the overall temperature distribution more even by significantly reducing the highest temperature of the blade surface,and reasonably matching the parameters of different coolant inlets.The results show that the proposed calculation methods can remarkably reduce the design cycle of complex turbine blade cooling structure.

BEM/FDM Conjugate Heat Transfer Analysis of a Two-dimensional Air-cooled Turbine Blade Boundary Layer

A coupled boundary element method （BEM） and finite difference method （FDM） are applied to solve conjugate heat transfer problem of a two-dimensional air-cooled turbine blade boundary layer. A loosely coupled strategy is adopted, in which each set of field equations is solved to provide boundary conditions for the other. The Navier-Stokes equations are solved by HIT-NS code. In this code, the FDM is adopted and is used to resolve the convective heat transfer in the fluid region. The BEM code is used to resolve the conduction heat transfer in the solid region. An iterated convergence criterion is the continuity of temperature and heat flux at the fluid-solid interface. The numerical results from the BEM adopted in this paper are in good agreement with the results of analytical solution and the results of commercial code, such as Fluent 6.2. The BEM avoids the complicated mesh needed in other computation method and saves the computation time. The results prove that the BEM adopted in this paper can give the same precision in numerical results with less boundary points. Comparing the conjugate results with the numerical results of an adiabatic wall flow solution, it reveals a significant difference in the distribution of metal temperatures. The results from conjugate heat transfer analysis are more accurate and they are closer to realistic thermal environment of turbines.

Lattice Boltzmann simulation of the effects of cavity structures and heater thermal conductivity on nucleate boiling heat transfer

The boiling heat transfer technology with cavity surfaces can provide higher heat flux under lower wall superheat,which is of great significance for the cooling of electronic chips and microelectromechanical devices.In this paper,the boiling characteristics of the cavity surfaces are investigated based on the lattice Boltzmann(LB)method,focusing on the effects of cavity shapes,sizes,and heater thermal conductivity on the heat transfer performance.The results show that the triangular cavity has the best boiling performance since it has less residual vapor and higher bubble departure frequency than those of the trapezoidal and rectangular cavities.As the cavity size increases,the enhancement of heat transfer by the cavity mouth is suppressed by the heat accumulation effect at the heater bottom.The liquid rewetting process during bubble departure is the reason for the fluctuation of the space-averaged heat flux,and the heater thermal conductivity determines the fluctuation amplitude.The evaporation of liquid in the cavity with high thermal conductivity walls is more intense,resulting in shorter waiting time and higher bubble departure frequency.

Investigation of the Conjugate Heat Transfer and Flow Field for a Flat Plate with Combined Film and Impingement Cooling

Film cooling combined with internal impingement cooling is one of the most effective technologies to protect the gas turbine vanes and blades from the hot gas. In this study, conjugate heat transfer CFD study was undertaken for a flat plate with combined film cooling and impingement cooling. An experiment on conjugate heat transfer of a flat plate with combined film and impingement cooling was performed to validate the code. Then the effects of several parameters including Biot number, blowing ratio, film hole shape and impingement hole diameter on the overall cooling effectiveness were numerically studied. The results show that for a specific combined cooling scheme and a given blowing ratio, the coolant potential can be reasonably allocated to the internal and the external cooling to achieve the overall cooling effectiveness. As the blowing ratio increases, the overall cooling effectiveness trends to reach a maximum value. For different film hole geometrical, the maximum values of the overall cooling effectiveness at high blowing ratio approximate to the same value. At a given mass flow rate of coolant, the increase of the impingement hole diameter leads to the reduction of the overall cooling effectiveness.

Conjugate Heat Transfer for Free Convection along a Vertical Plate Fin

In this study,a new and effective improved Semi-Analytic and Semi-Empirical formula f(Pr)= (0.749999437Pr^(1/2))/((0.609+1.221Pr^(1/2)+1.238Pr)^(1/4))has been proposed to solve a conjugate problem with free convection in the incompressible laminar boundary layer flow and heat conduction in a solid wall for the flow passing a flat plate fin. A combination of flat-plate flow and flat-plate fin heat conduction has been considered in the present study.Finite -difference solutions for the interface temperature profiles and the heat transfer rates have been presented over the entire thermo-fluid-dynamic field for Prandtl numbers from 0.001 to 10000.First,the similar flow field has been solved by the Runge-Kutta method and the shooting methods,then the correlation equation of the local heat transfer coefficient have been obtained.Finally,the empirical formula has been substituted into the fin temperature heat conduction calculation processes to obtain the iterative solutions of the conjugate problems.

Conjugate heat transfer investigation of cooled turbine using the preconditioned density-based algorithm

The preconditioned density-based conjugate heat transfer(CHT)algorithm was used to investigate the heat transfer characteristics of a cooled turbine vane.Fluid domain provided boundary heat flux for solid domain and obtained boundary temperature from it for the coupling strategy.The governing equations were solved by the preconditioned density-based finite-volume method,with preconditioning matrix,improved Abu-Gharmam Shaw(AGS)transition model,matrix dissipation scheme and four kinds of turbulence models.The grid system is multi-block structured grids for fluid domain and unstructured grids for solid domain,with full-matched grids at the fluid-solid interfaces.The effects of turbulence model,outlet Mach number,outlet Reynolds number,inlet turbulence intensity and the temperature ratio of blade surface/gas on the local heat transfer performance were studied.Results indicate that the k-o shear-stress transport(SST)and AGS model can predict the conjugate heat transfer better than others.The Mach number and Reynolds number have relatively obvious influences on the heat transfer,while the turbulence intensity and temperature ratio only have slight influences.Comparisons with experimental data demonstrate the applicability and accuracy of the numerical algorithm.

Conjugate heat transfer investigations of turbine vane based on transition models

The accurate simulation of boundary layer transition process plays a very important role in the prediction of turbine blade temperature field. Based on the Abu-Ghannam and Shaw （AGS） and c-Re h transition models, a 3D conjugate heat transfer solver is developed, where the fluid domain is discretized by multi-block structured grids, and the solid domain is discretized by unstructured grids. At the unmatched fluid/solid interface, the shape function interpolation method is adopted to ensure the conservation of the interfacial heat flux. Then the shear stress transport （SST） model, SST ＆ AGS model and SST ＆ c-Re h model are used to investigate the flow and heat transfer characteristics of Mark II turbine vane. The results indicate that compared with the full turbulence model （SST model）, the transition models could improve the prediction accuracy of temperature and heat transfer coefficient at the laminar zone near the blade leading edge. Compared with the AGS transition model, the c-Re h model could predict the transition onset location induced by shock/boundary layer interaction more accurately, and the prediction accuracy of temperature field could be greatly improved.

Conjugate Heat Transfer Investigation on the Cooling Performance of Air Cooled Turbine Blade with Thermal Barrier Coating

A hot wind tunnel of annular cascade test rig is established for measuring temperature distribution on a real gas turbine blade surface with infrared camera.Besides,conjugate heat transfer numerical simulation is performed to obtain cooling efficiency distribution on both blade substrate surface and coating surface for comparison.The effect of thermal barrier coating on the overall cooling performance for blades is compared under varied mass flow rate of coolant,and spatial difference is also discussed.Results indicate that the cooling efficiency in the leading edge and trailing edge areas of the blade is the lowest.The cooling performance is not only influenced by the internal cooling structures layout inside the blade but also by the flow condition of the mainstream in the external cascade path.Thermal barrier effects of the coating vary at different regions of the blade surface,where higher internal cooling performance exists,more effective the thermal barrier will be,which means the thermal protection effect of coatings is remarkable in these regions.At the designed mass flow ratio condition,the cooling efficiency on the pressure side varies by 0.13 for the coating surface and substrate surface,while this value is 0.09 on the suction side.

Bi-Fo time scaling method in the numerical simulation of transient conjugate heat transfer

Reliable transient thermal analysis plays a very important role in the engine safety analysis.Transient conjugate heat transfer simulation is an important way of temperature analysis.But there exists a great disparity in the time scales between solid conduction and fluid convection.The calculation cost of transient conjugate heat transfer analysis is very huge because of the tiny time step of computational fluid dynamics.The Bi-Fo time scaling method is proposed to improve the computational efficiency of transient conjugate heat transfer.On the one hand,this method carries out a similar transformation on solid heat conduction,scaling the calculation time with the product of density and specific heat capacity to maintain the consistency of Fourier number.On the other hand,it takes very short time for the fluid domain to recover stability after a boundary disturbance.Based on the above characteristic,the flow time is directly compressed to the same as that of the solid domain.It is verified by Mark II vane that increasing the solid thermal diffusivity can reduce the time scale of heat conduction.In the situation of rapidly stable flow field,scaling flow time does not affect the solid thermal boundary under corresponding dimensionless time.Within the application scope,the Bi-Fo time scaling method can greatly reduce the time cost of transient conjugate heat transfer simulation while maintaining the accuracy of transient temperature analysis.

Conjugate Heat Transfer Characterization in Cooling Channels

Cooling technology of gas turbine blades,primarily ensured via internal forced convection,is aimed towards withdrawing thermal energy from the airfoil.To promote heat exchange,the walls of internal cooling passages are lined with repeated geometrical flow disturbance elements and surface non-uniformities.Raising the heat transfer at the expense of increased pressure loss;the goal is to obtain the highest possible cooling effectiveness at the lowest possible pressure drop penalty.The cooling channel heat transfer problem involves convection in the fluid domain and conduction in the solid.This coupled behavior is known as conjugate heat transfer.This experimental study models the effects of conduction coupling on convective heat transfer by applying iso-heat-flux boundary condition at the external side of a scaled serpentine passage.Investigations involve local temperature measurements performed by Infrared Thermography over flat and ribbed slab configurations.Nusselt number distributions along the wetted surface are obtained by means of heat flux distributions,computed from an energy balance within the metal domain.For the flat plate experiments,the effect of conjugate boundary condition on heat transfer is estimated to be in the order of 3%.In the ribbed channel case,the normalized Nusselt number distributions are compared with the basic flow features.Contrasting the findings with other conjugate and convective iso-heat-flux literature,a high degree of overall correlation is evident.