Experimental Verification of Model for Liquid-Cooled Staggered Pin Fin Heat Sinks with Top Bypass Flow

Pressure drops and heat transfer over staggered pin fin heat sinks with top bypass flow were experimentally evaluated. The authors considered liquid-cooling applications because there were few data available comparing to air-cooling applications. Empirical equations to predict heat transfer on the endwall were developed by obtaining experimental data on the copper base plate with acrylic pins. A new model for predicting pressure drops and heat transfer over staggered pin fin heat sinks with top bypass flow based on mass, momentum, and energy conservation within the two control volumes is proposed. The first control volume in the model is located within the finned area, and the second is located in the gap between the tip of the pins and the flow channel. This model combines two conditions according to the boundary-layer thickness. A comparison between experimental and calculated results revealed that dimensionless pressure drops and the Nusselt number could be predicted within 30% error for the former and 50% error for the latter.

Investigation of Liquid Cooling Plate for Server CPUs Based on Topology Optimization

In this study, a microchannel liquid cooling plate (LCP) is proposed for Intel Xeon 52.5 mm * 45 mm packaged architecture processors based on topology optimization (TO). Firstly, a mathematical model for topology optimization design of the LCP is established based on heat dissipation and pressure drop objectives. We obtain a series of two-dimensional (2D) topology optimization configurations with different weighting factors for two objectives. It is found that the biomimetic phenomenon of the topologically optimized flow channel structure is more pronounced at low Reynolds numbers. Secondly, the topology configuration is stretched into a three-dimensional (3D) model to perform CFD simulations under actual operating conditions. The results show that the thermal resistance and pressure drop of the LCP based on topology optimization achieve a reduction of approximately 20% - 50% compared to traditional serpentine and microchannel straight flow channel structures. The Nusselt number can be improved by up to 76.1% compared to microchannel straight designs. Moreover, it is observed that under high flow rates, straight microchannel LCPs exhibit significant backflow, vortex phenomena, and topology optimization structures LCPs also tend to lead to loss of effectiveness in the form of tree root-shaped branch flows. Suitable flow rate ranges for LCPs are provided. Furthermore, the temperature and pressure drop of experimental results are consistent with the numerical ones, which verifies the effectiveness of performance for topology optimization flow channel LCP.

Laser surface melting AZ31B magnesium alloy with liquid nitrogen-assisted cooling

Laser surface melting（LSM） is a high-energy surface treatment that allows modification of the microstructure and surface properties of Mg alloys. In the present work, an attempt of LSM on magnesium alloy with liquid nitrogen-assisted cooling（LNSC） was carried out to get the higher cooling rate and improve the surface properties. The experimental results were compared with those of Ar gas protection at room temperature. The samples after LSM with LNSC resulted in a thinner melted layer, a highly homogeneous, refined melted microstructure and formed a lot of worm-like nanocrystals and local amorphous structures. Microhardness of the melted layer with LNAC was improved to HV 90-148 as compared to HV 65-105 of the samples with Ar gas protection. The corrosion resistance of the melted layer in a 3.5% Na Cl solution（mass fraction） was improved because of the grain refinement and redistribution of β-Mg17Al12 phases following rapid quenching associated with the process.

Directional Solidification Assisted by Liquid Metal Cooling

An overview of the development and current status of the directional solidification process assisted by liquid metal cooling （LMC） has been presented in this paper. The driving force of the rapid development of the LMC process has been analyzed by considering the demands of （1） newer technologies that can provide higher thermal gradients for alleviated segregation in advanced alloy systems, and （2） better production yield of the large directionally solidified superalloy components. The brief history of the industrialization of the LMC process has been reviewed, followed by the discussion on the LMC parameters including selection of the cooling media, using of the dynamic baffle, and the influence of withdrawal rates and so on. The microstructure and mechanical properties of the traditional superalloys processed by LMC, as well as the new alloys particularly developed for LMC process were then described. Finally, future aspects concerning the LMC process have been summarized.

CUTTING REGULARITY AND DISCHARGE CHARACTERISTICS BY USING COMPOSITE COOLING LIQUID IN WIRE CUT ELECTRICAL DISCHARGE MACHINE WITH HIGH WIRE TRAVELING SPEED

The analysis of cutting regularity is provided through using and comparing two typical cooling liquids. It is proved that cutting regularity is greatly affected by cooling liquid＇s washing ability. Discharge characteristics and theoretic analysis between two electrodes are also discussed based on discharge waveform. By using composite cooling liquid which has strong washing ability, the efficiency in the first stable cutting phase has reached more than 200 mm^2/min, and the roughness of the surface has reached Ra〈0.8 μm after the fourth cutting with more than 50 mm^2/min average cutting efficiency. It is pointed out that cutting situation of the wire cut electrical discharge machine with high wire traveling speed （HSWEDM） is better than the wire cut electrical discharge machine with low wire traveling speed （LSWEDM） in the condition of improving the cooling liquid washing ability. The machining indices of HSWEDM will be increased remarkably by using the composite cooling liquid.

Research on Performance Optimization of Liquid Cooling and Composite Phase Change Material Coupling Cooling Thermal Management System for Vehicle Power Battery

The serpentine tube liquid cooling and composite PCM coupled cooling thermal management system is designed for 18650 cylindrical power batteries,with the maximum temperature and temperature difference of the power pack within the optimal temperature operating range as the target.The initial analysis of the battery pack at a 5C discharge rate,the influence of the single cell to cooling tube distance,the number of cooling tubes,inlet coolant temperature,the coolant flow rate,and other factors on the heat dissipation performance of the battery pack,initially determined a reasonable value for each design parameter.A control strategy is used to regulate the inlet flow rate and coolant temperature of the liquid cooling system in order to make full use of the latent heat of the composite PCM and reduce the pump’s energy consumption.The simulation results show that the maximum battery pack temperature of 309.8 K and the temperature difference of 4.6 K between individual cells with the control strategy are in the optimal temperature operating range of the power battery,and the utilization rate of the composite PCM is up to 90%.

Studying Cu Alloy Corrosion Products in Cooling Liquid

The effect of cooling liquid used for heat exchangers on the Cu alloy corrosion products has been examined using potential-time measurements under applied current condition (anodizing), potentiodynamic polarization, X-ray diffraction (XRD) and infrared spectroscopy (IR) The corrosion products formed on the Cu alloy surface during anodizing, are Cu2O, Cu2(OH)3Cl, and Cu2S. NaCl is detected in the corrosion products. The film formation depends on the applied current and the shift of potential to nobler direction indicates its formation progress.

Thermal Simulation for Two-Phase Liquid Cooling 3D-ICs

This work presents an algorithm for simulating more accurate temperature distribution in two-phase liquid cooling for three-dimensional integrated circuits than the state of-the-art methods by utilizing local multi-linear interpolation techniques on heat transfer coefficients between the microchannel and silicon substrate, and considering the interdependence between the thermal conductivity of silicon and temperature values. The experimental results show that the maximum and average errors are only 9.7% and 6.7% compared with the measurements, respectively.

Research on Thermal Management Control Strategy of Electric Vehicle Liquid Cooling Battery Pack

Due to the risk of thermal runaway in the charging and discharging process of a soft packed lithium battery pack for electric vehicles,a stamping channel liquid cooling plate cooling system is designed,and then the heat dissipation problem of the battery pack is solved through reasonable thermal management control strategy.Using computational fluid dynamics simulation software star-CCM+,the thermal management control strategy is optimized through simulation technology,and the temperature field distribution of battery pack is obtained.Finally,an experimental platform is built,combined with experiments,the effectiveness of the thermal management control strategy of the cooling system is verified.The results show that when the battery pack is in the environment of 25℃,the maximum temperature of the cooling system can be lower than 40℃,the maximum temperature difference between all single batteries is within 5℃,and the maximum temperature difference between inlet and outlet coolant is 3℃,which can meet the heat dissipation requirements of the battery pack and prevent out of control heat generation.

Design and analysis of an advanced thermal management system for the solar close observations and proximity experiments spacecraft

In this paper,the mission and the thermal environment of the Solar Close Observations and Proximity Experiments(SCOPE)spacecraft are analyzed,and an advanced thermal management system(ATMS)is designed for it.The relationship and functions of the integrated database,the intelligent thermal control system and the efficient liquid cooling system in the ATMS are elaborated upon.For the complex thermal field regulation system and extreme space thermal environment,a modular simulation and thermal field planning method are proposed,and the feasibility of the planning algorithm is verified by numerical simulation.A solar array liquid cooling system is developed,and the system simulation results indicate that the temperatures of the solar arrays meet the requirements as the spacecraft flies by perihelion and aphelion.The advanced thermal management study supports the development of the SCOPE program and provides a reference for the thermal management in other deep-space exploration programs.

Numerical modelling rock deformation subject to nitrogen cooling to study permeability evolution

How to model the permeability evolution of rock subjected to liquid nitrogen cooling is a key issue. This paper proposes a simple but practical method to study the permeability evolution of rocks subject to liquid nitrogen cooling. FLAC with FISH function was employed to numerically model the rock behavior under cooling. The enhanced perme- ability of the volumetric strain was defined, and the permeability was directly evaluated based on element＇s volumetric strain. Detailed procedures for implementing the evolution model of permeability in this paper were presented. A case study was carried out to simulate a coal bed where liquid nitrogen was injected in the bore hole. And a semi-submerged test of liquid nitrogen was performed. The method to model the permeability evolution of rocks subject to liquid nitrogen shock in this paper was proved to be right by the test results. This simulation results are discussed with the hope to provide some insight into understanding the nitrogen cooling practice.

Performance analysis and optimization of free cooling strategies for a liquid-cooled data center

The increasing power density of IT electronics and the enormous energy consumption of data centers lead to the urgent demand for efficient cooling technology.Due to its efficiency and safety,liquid-cooled heat sink technology may gradually replace air-cooled technology over time.With the ambient or higher water supply temperature,the liquid-cooled technology shortens the operating time of the chiller and improves its coefficient of performance,while the pump power consumption may increase for satisfying the constant cooling capacity.Therefore,it is significant to study the optimal water supply temperature to achieve energy-efficient operation of data centers.A virtual 30.1 kW data center is considered as the case,the liquid-cooled system is constructed with a combination of innovative manifold microchannel heat sink with oblique fins and indirect evaporative cooling technology to minimize energy consumption.A hybrid thermal management model integrating the heat dissipation model and the power consumption model is established by TRNSYS and FLUENT software.To the highest chip-safe operating temperature premise,the energy performance is analyzed under various water supply temperatures in Guangzhou.The result shows that only 21.5-hour mechanical cooling is needed with the 30℃server inlet temperature throughout the year.And the minimized power consumption occurs with the constant 29℃server inlet temperature.Moreover,the temperature adaptive control strategy(TACS)is adopted to test the cooling system power consumption under different regulation frequencies,and the by-week TACS can achieve another 11.5%energy saving than the minimum power consumption of the constant temperature control strategy.

A new marine propulsion system

A new marine propulsion system is proposed . A small liquid sodium cooled reactor acts as prime mover; alkali-metal thermal-to-electric conversion ( AMTEC) cells are employed to convert the heat energy to electricity; superconducting magneto-hydrodynamic thruster combined with spray-water thruster works as pr opulsion. The configuration and characteristics of this system are described. Such a nuclear-powered propulsion system is not only free of noise, but also has high reliability and efficiency. It would be a preferable propulsion system for ships in the future.

Additive Manufacturing of Liquid-Cooled Ceramic Heat Sinks:An Experimental and Numerical Study

With recent advances in power electronic packaging technologies,liquid-cooled ceramic heat sinks have been considered as a promising solution for further improving the performance of power electronic devices.In this study,several aluminum oxide heat sinks were fabricated and tested using the digital light processing-based ad-ditive manufacturing method,to verify their practical performance.The results showed that the complex cooling structures inside the heat sinks can be completely formed and exhibited high surface quality.The experimental thermal and hydraulic performances of the heat sinks were consistent with the numerically modeled predictions.Furthermore,by exploiting the advantages of additive manufacturing,a direct manifold microchannel(MMC)configuration was designed to reduce the vertical flow of the traditional MMC configuration and achieve an im-proved cooling efficiency.At a constant volumetric flow rate of 1 L/min,the direct MMC configuration achieved a 19.8%reduction in pressure drop and an 11.8%reduction in thermal resistance,as well as a more uniform temperature distribution.

Experimental study on the mechanism of flow blockage formation in fast reactor

Various sources of solid particles might exist in the coolant flow of a liquid metal cooled fast reactor(e.g.,through chemical interaction between the coolant and impurities,air,or water,through corrosion of structural materials,or from damaged/molten fuel).Such particles may cause flow blockage accidents in a fuel assembly,resulting in a reduction in coolant flow,which potentially causes a local temperature rise in the fuel cladding,cladding failure,and fuel melt.To understand the blockage formation mechanism,in this study,a series of simulated experiments was conducted by releasing different solid particles from a release device into a reducer pipe using gravity.Through detailed analyses,the influence of various experimental parameters(e.g.,particle diameter,capacity,shape,and static friction coefficient,and the diameter and height of the particle release nozzle)on the blockage characteristics(i.e.,blockage probability and position)was examined.Under the current range of experimental conditions,the blockage was significantly influenced by the aforementioned parameters.The ratio between the particle diameter and outlet size of the reducer pipe might be one of the determining factors governing the occurrence of blockage.Specifically,increasing the ratio enhanced blockage(i.e.,larger probability and higher position within the reducer pipe).Increasing the particle size,particle capacity,particle static friction coefficient,and particle release nozzle diameter led to a rise in the blockage probability;however,increasing the particle release nozzle height had a downward influence on the blockage probability.Finally,blockage was more likely to occur in non-spherical particles case than that of spherical particles.This study provides a large experimental database to promote an understanding of the flow blockage mechanism and improve the validation process of fast reactor safety analysis codes.

Microstructural evolution of directionally solidified DZ125 superalloy castings with different solidification methods

The properties of Ni-base superalloy castings microstructure, and different solidification methods have are closely related to the uniformity of their as-cast serious effect on microstructural uniformity. In this paper, the influences of high rate solidification （HRS） process （with or without superheating） and liquid metal cooling （LMC） process on the microstructure of DZ125 superalloy were investigated. Blade-shape castings were solidified at rates of 40 pm.s-1 to 110 tJm.s1 using HRS process and a comparative experiment was carried out at a rate of 70 IJm.s1 by LMC process. The optical microscope （OM）, scanning electron microscope （SEM） were used to observe the microstructure and the grain size was analyzed using electron back scattered diffraction （EBSD） technique. Results show that for the castings by either HRS or LMC process, the primary dendrite arm spacing and size of 7＇ precipitates decrease with increasing the withdrawal rate; the dendrites and 7＇ precipitates at the upper section of the blade are coarser than those in the middle, especially for the HRS castings without high superheating technique. When the withdrawal rate is 70 iJm.s1, the castings by HRS with high superheating technique have the smallest PDAS with fine 7＇ precipitates; while the size distribution of 7＇ precipitates is more homogenous in LMC castings, and the number of larger grains in LMC castings is smaller than that in the HRS castings. Moreover, high superheating technique yields smaller grains in the castings. Both the LMC method and HRS with high superheating technique can be used to prepare castings with reduced maximum grain size.

Liquid phase 3D printing for quickly manufacturing conductive metal objects with low melting point alloy ink

Conventional 3D metal printings are generally time-consuming as well as lacking of high performance printable inks.From an alternative way,here we proposed the method of liquid phase 3D printing for quickly making conductive metal objects.Through introducing metal alloys whose melting point is slightly above room temperature as printing inks,several representative structures spanning from one,two and three dimension to more complex patterns were demonstrated to be quickly fabricated.Compared with the air-cooling in a conventional 3D printing,the liquid-phase-manufacturing offers a much higher cooling rate and thus significantly improves the speed in fabricating the target metal objects.This unique strategy also efficiently prevents the liquid metal inks from air oxidation,which is hard to avoid otherwise in an ordinary 3D printing.The key physical factors(such as properties of the cooling fluid,air pressure within the syringe barrel and needle diameter,types and properties of the printing ink)and several interesting intermediate fluids interaction phenomena between liquid metal and conventional cooling fluids such as water or ethanol,which evidently affecting the printing quality,were disclosed.In addition,a basic route to make future liquid phase 3D printer incorporated with both syringe pump and needle arrays was also suggested.The liquid phase 3D printing,which owns potential values not available in a conventional method,opens an efficient way for quickly making conductive metal objects in the coming time.

Liquid metal as energy transportation medium or coolant under harsh environment with temperature below zero centigrade

The current highly integrated electronics and energy systems are raising a growing demand for more sophisticated thermal management in harsh environments such as in space or some other cryogenic environment. Recently, it was found that room temperature liquid metals （RTLM） such as gallium or its alloys could significantly reduce the electronics temperature compared with the conventional coolant, like water, oil or more organic fluid. However, most of the works were focused on RTLM which may subject to freeze under low temperature. So far, a systematic interpretation on the preparation and thermal properties of liquid metals under low temperature （here defined as lower than O^C） has not yet been available and related applications in cryogenic field have been scarce. In this paper, to promote the research along this important direction and to overcome the deficiency of RTLM, a comprehensive evaluation was proposed on the concept of liquid metal with a low melting point below zero centigrade, such as mercury, alkali metal and more additional alloy candidates. With many unique virtues, such liquid metal coolants are expected to open a new technical frontier for heat transfer enhancement, especially in low temperature engineering. Some innovative ways for making low melting temperature liquid metal were outlined to provide a clear theoretical guideline and perform further experiments to discover new materials. Further, a few promising applied situations where low melting temperature liquid metals could play irreplaceableroles were detailed. Finally, some main factors for optimization of low temperature coolant were summarized. Overall, with their evident merits to meet various critical requirements in modem advanced energy and power industries, liquid metals with a low melting temperature below zero centigrade are expected to be the next- generation high-performance heat transfer medium in thermal managements, especially in harsh environment in space.

Operation Optimization of Liquid Cooling Systems in Data Centers by the Heat Current Method and Artificial Neural Network

Liquid cooling systems in data centers have been attracting more attentions due to its better cooling capability and less energy consumption. In order to propose an effective optimization method for the operation of indirect liquid cooling systems, this paper first constructs an experiment platform and applies the heat current method to build the global heat transfer constraints of the whole system. Particularly, the thermal conductance of each heat exchanger under different working conditions is predicted by the Artificial Neural Networks(ANN) trained by the historical data. On this basis, combining the heat transfer and fluid flow constraints together with the Lagrange multiplier method builds the optimization model with the objective of minimum pumping power consumption(PPC), solving which by the solution strategy designed obtains the optimal frequencies of the variable frequency pumps(VFPs). Operating with the optimal and other feasible operating conditions validates the optimization model. Meanwhile, the experiments with variable heat loads and flow resistances provide some guidelines for the optimal system operation. For instance, to address heat load increase of a branch, it needs to increase the frequencies of the VFPs, not only the corresponding hot loop but also the whole cold loop.

Experimental investigation on a novel liquid cooling device for a prismatic Li-ion battery module operating at high ambient temperature

A novel liquid cooling device for a prismatic LiFePO4 battery module was proposed and manufactured in this study in order to improve the thermal management performance of the battery module operating at high ambient temperature.A testing system was set up to experimentally measure temperatures in different locations of the battery module consisting of seven 60 Ah cells.Tests were conducted to investigate both the passive and active cooling performances of the proposed system at different ambient temperatures and discharging rates in regarding with the maximum temperature and difference between the maximum and minimum temperatures.The results clearly show that both the ambient temperature and discharging rate play important role on the maximum temperature of the battery module.Passive cooling cannot meet the cooling requirement of the battery module particularly at high ambient temperature of 40℃.In contrary,liquid cooling can successfully reduce the maximum temperature to the required temperature range of the battery module even in high temperature environment and relatively high discharging rate.The effect of water inlet temperature on the cooling performance was also experimentally studied.With the inlet temperature of 28℃,the active cooling device can reduce the maximum temperature of the battery module to about 34.8℃after discharging at 0.6℃for 1000 s.The temperature difference of only 3.8℃was also achieved which suggests a great uniform distribution of temperature in the battery module.