Flow equation and similarity criterion during centrifugal casting in micro-channel

Liquid metal filling flow process in the microscale during the centrifugal casting process was studied by means of similar physical simulation. The research was focused on derived similarity criterion. Based on the traditional flow equations, the flow equation and the Bernoulli＇s equation for liquid metal flows in micro-scale space were derived, which provides a mathematical model for numerical simulation of micro-scale flow. In the meanwhile, according to the micro-flow equation and the similarity theory, the similarity criterion for the physical simulation of the mold filling behaviors was presented under centrifugal force field, so as to achieve the visual observation and quantitative analysis of micro-flow process.

电力电子器件用液冷针翅散热器的研究进展

随着大功率电力电子器件(如绝缘栅双极型晶体管,IGBT)轻量化、小型化和集成化的发展需求,其功率密度越来越大,导致其热流密度越来越高,亟需高效散热来满足其使用要求。传统空气冷却散热器结构简单、使用方便,但是散热能力较低,难以满足高热流密度的散热需求,目前主要采用液体冷却散热器,其中液冷针翅散热器是最常用的高效散热器。本文介绍了液冷针翅散热器的结构、液体工质、材料和制造等方面的研究进展,重点分析了液冷针翅散热器的流体通道结构、针翅结构对流动和传热性能的影响,并给出了液冷针翅散热器的发展建议。

Solid-phase sintering process and forced convective heat transfer performance of porous-structured micro-channels

A solid-phase sintering process for the low-cost fabrication of composite micro-channels was developed. Three kinds of composite micro-channels with metallic porous structures were designed. The sintering process was studied and optimized to obtain porous-structured micro-channels with high porosity. The flow resistance and heat transfer performance in the composite micro-channels were investigated. The composite micro-channels show acceptable flow resistance, significant enhancement of heat transfer and dramatic improvement of flow boiling stability, which indicates a promising prospect for the application in forced convective heat transfer.

风冷IGBT散热器正交设计及优化研究

基于某工程功率器件的散热需求及散热器尺寸限制要求,拟寻求一种性能较优的散热设计方案。结合散热基本理论,采用自下而上、紧凑型设计为原则,通过正交分析的方式设计并对比了不同结构方案下散热器的基本性能,结果表明:综合考虑散热性能及风机选型风压限制等因素,外形结构尺寸中,散热器长度对散热器风阻及热阻性能的影响最大;散热基板及翅片尺寸也存在优选范围,综合生产制造工艺,散热翅片厚度优选推荐值为2~4 mm;散热器采用引风方式更有利于散热设计,IGBT到出风侧的距离与其相邻间距比值在1~2时散热性能相对较优。优化后的散热器方案对比设计限值,散热性能提升16%且占用体积下降64.43%。

Similar physical simulation of microflow in micro-channel by centrifugal casting process

By means of similar physical simulation, liquid metal filling flow pattern in the microscale during the centrifugal casting process was studied. It was found that, in microscale, the flow channel with the maximum cross-sectional area was filled first, and the micro flow channels with 0.1 mm in diameter were filled when the rotational speed was increased to 964 r/min. The total fluid energy remained constant during the mould filling, and the changes of cross-sectional area only occurred in the microflow channels with 0.3 mm in diameter. Filling velocity increased with processing time, and a peak value was achieved rapidly, followed by a gentle increase as the process proceeded further. The time required to achieve the peak filling rate decreased dramatically with increase of rotational speed.

功率变换器风冷系统优化的仿真研究

针对高功率密度半导体开关器件的温升问题,研究了功率变换器的风冷系统散热性能表现,基于ANSYS ICEPAK仿真分析了热界面材料(Thermal interface material,TIM)对分立式SiC MOSFET温升以及散热器热阻的影响作用,提出了三种风道设计方案,从风机效率、降温效果、多器件温度一致性三个方面给出综合评价。研究结果表明,TIM热导率越高,SiC芯片温度越低,但温度的下降存在极限,氮化铝陶瓷垫片与常规硅胶片相比可降温约14.2%;散热器热阻与TIM热导率呈变化率递减的非线性关系,过高热导率的实际意义有限,应结合热设计成本综合考虑TIM选择;合理分配风机风量比单纯提高气流速度的散热效果更佳,混合射流的变截面双风道设计方案具备更高的风机效率以及良好的温度一致性,与无风道相比芯片温度可再次降低约13.7%,其综合表现最优。研究工作为后续开展功率开关器件的热管理试验提供了参考依据。

Micromixing Efficiency of Viscous Media in Micro-channel Reactor

Micromixing efficiency of viscous media in Y-type micro-channel reactor was studied by using iodide-iodate test reaction as working system.Experiments were carried out in water-glycerin mixtures with 7 different viscosities.The experimental results showed that segregation index of the micro-channel reactor increases with the decrease of volumetric flow rate and the increase of solution viscosity.Based on the incorporation model,the micromixing time tm of the micro-channel reactor was estimated in the range of 10-4-10-3s at different viscosities,which indicated that the micro-channel reactor possesses a much better micromixing performance compared to the stirred tank(tm=0.02-0.2s).

Correlations Based on CFD and Their Applications in Optimization for Staggered and Parallel Plate Fin Heatsinks

Both parallel and staggered plate fin arrays have shown promise for use inhigh performance heatsinks regard of its individual manufacturing costs. The geometrical andoperational parameters are very important to their cooling performance as heatsinks in practicalapplications. Fluent 5.0 commercial CFD (computational fluid dynamic) code is used to simulate theflow and heat transfer of those heatsinks of different realistic parameters. Based on thosesimulations, two correlations, concerning Nusselt number and friction factor as the functions ofgeometrical and operational parameters, FB (fin-base area ratio), PR' (ratio of spanwise pitch tolengthwise pitch) and Re, were developed. From the both, the performance comparisons for optimizinggeometrical and operational parameters of a fixed dimension heatsink are shown at constant pumpingpower and constant thermal resistance. Several optimized parameters were obtained can out performthe staggered ones.

Improved catalytic performance of Ni catalysts for steam methane reforming in a micro-channel reactor

Milliseconds process to produce hydrogen by steam methane reforming （SMR） reaction, based on Ni catalyst rather than noble catalyst such as Pd, Rh or Ru, in micro-channel reactors has been paid more and more attentions in recent years. This work aimed to further improve the catalytic performance of nickel-based catalyst by the introduction of additives, i.e., MgO and FeO, prepared by impregnation method on the micro-channels made of metal-ceramic complex substrate. The prepared catalysts were tested in the same micro-channel reactor by switching the catalyst plates. The results showed that among the tested catalysts Ni-Mg catalyst had the highest activity, especially under harsh conditions, i.e., at high space velocity and/or low reaction temperature. Moreover, the catalyst activity and selectivity were stable during the 12 h on stream test even when the ratio of steam to carbon （SIC） was as low as 1.0. The addition of MgO promoted the active Ni species to have a good dispersion on the substrate, leading to a better catalytic performance for SMR reaction.

NUMERICAL ANALYSIS OF GASEOUS FLOW IN MICRO-CHANNELS

The algorithm of gaseous flow in bi-dimensional micro-channels is set up andthe corresponding program based on micro-flow theory is presented. Gaseous flow in micro-channels isnumerically analyzed and the pressure drop along the duct as well .as the velocity profile in themicro-channels is obtained. The numerical results agreed well with the experimental results in thereferences. Moreover, the effects of Kn, sigma_v and Re on the velocity profiles are analyzed. It isfound that for Kn>0.001, with increasing Kn number, the slip velocity on the wall boundaryincreases; the tangential momentum coefficient sigma_v affects the slip velocity greatly. The slipvelocity increases with decreasing a, In the slip flow regime and for low Re numbers, the slipvelocity is little influenced by the Re number.

RESEARCH ON DIFFUSION IN MICRO-CHANNEL FLOW DRIVEN BY ELECTROOSMOSIS

Numerical simulation using the finite differential method was carried out to analyze the diffusion of an impulse sample in the micro-channel driven by electroosmosis. The results show that the electrical field strength applied externally and the concentration of buffer solution play a significant role in the diffusion of sample, however, hydraulic diameter and aspect ratio of height to width of channel play a small role in it. Weakening the electrical field strength applied externally and the concentration of buffer solution properly can prevent the sample band from broadening effectively, and promote the efficiency of testing and separation as well as keep a faster speed of transport. The conclusions are helpful to the optimal design for micro-channel.

Flow characteristics of supersonic gas passing through a circular micro-channel under different inflow conditions

Gas flow in a micro-channel usually has a high Knudsen number. The predominant predictive tool for such a microflow is the direct simulation Monte Carlo(DSMC) method, which is used in this paper to investigate primary flow properties of supersonic gas in a circular micro-channel for different inflow conditions, such as free stream at different altitudes, with different incoming Mach numbers, and with different angles of attack. Simulation results indicate that the altitude and free stream incoming Mach number have a significant effect on the whole micro-channel flow field, whereas the angle of attack mainly affects the entrance part of micro-channel flow field. The fundamental mechanism behind the simulation results is also presented. With the increase of altitude, thr free stream would be partly prevented from entering into micro-channel.Meanwhile, the gas flow in micro-channel is decelerated, and the increase in the angle of attack also decelerates the gas flow. In contrast, gas flow in micro-channel is accelerated as free stream incoming Mach number increases. A noteworthy finding is that the rarefaction effects can become very dominant when the free stream incoming Mach number is low. In other words, a free stream with a larger incoming velocity is able to reduce the influence of the rarefaction effects on gas flow in the micro-channel.

CFD simulation of homogeneous reaction characteristics of dehydration of fructose to HMF in micro-channel reactors

In this work the applicability of the micro-channel reactor technique to the production of promising platform chemical 5-hydroxymethyl furan(HMF) from fructose in aqueous solution is systemically investigated by performing CFD simulations.Influential factors including solvents,residence time distribution of reaction mixtures,heat transfer conditions and micro-channel configurations are evaluated in terms of the reaction performance indices,i.e.,conversion of fructose,HMF selectivity and yield.A scale-up method from a single channel to a multiple channel reactor is also proposed.It is demonstrated that:1) at the single channel scale,controlling residence times and temperature distribution of the reaction mixture within the channel is crucial for enhancing the reaction performance,while different channel configurations lead to marginal improvements;2) for the scaling-up of the reaction process,a reactor module containing 15 circular parallel channels could be used as module blocks,which can be stacked one by one to meet the required reactor performance and production capacity.The present results show that micro-reactors are quite suitable for HMF production.

Flowing simulation of injection molded parts with micro-channel

In the micro-molding of component with a micro-sized channel, the ability for polymer melt to flowing into the micro-channel in a macro-sized part is a big challenge. The multidimensional flow behaviors are included in the injection molding the macro-component with a micro-channel. In this case, a simplified model is used to analyze the flow behaviors of the macro-sized part within a micro-channel. The flow behaviors in the macro-cavity are estimated by using the finite element and finite difference methods. The influence of the injection rate, micro-channel size, heat transfer coefficient, and mold temperature on the flowing distance is investigated based on the non-isothermal analytic method. The results show that an increase in the radius of the micro-channel and mold temperature can improve effectively the flowing distance in the micro-channel.

Modelling two-layer nanofluid flow in a micro-channel with electro-osmotic effects by means of Buongiorno’s model

A fully developed steady immiscible flow of nanofluid in a two-layer microchannel is studied in the presence of electro-kinetic effects.Buongiorno’s model is employed for describing the behavior of nanofluids.Different from the previous studies on two-layer channel flow of a nanofluid,the present paper introduces the flux conservation conditions for the nanoparticle volume fraction field,which makes this work new and unique,and it is in coincidence with practical observations.The governing equations are reduced into a group of ordinary differential equations via appropriate similarity transformations.The highly accurate analytical approximations are obtained.Important physical quantities and total entropy generation are analyzed and discussed.A comparison is made to determine the significance of electrical double layer(EDL)effects in the presence of an external electric field.It is found that the Brownian diffusion,the thermophoresis diffusion,and the viscosity have significant effects on altering the flow behaviors.

Modeling and Simulation of a Hybrid Jet-Impingement/Micro-Channel Heat Sink

With the progressive increase in the number of transistors that can be accommodated on a single integrated circuit,new strategies are needed to extract heat from these devices in an efficient way.In this regard methods based on the combination of the so-called“jet impingement”and“micro-channel”approaches seem extremely promising for possible improvement and future applications in electronics as well as the aerospace and biomedical fields.In this paper,a hybrid heat sink based on these two technologies is analysed in the frame of an integrated model.Dedicated CFD simulation of the coupled flow/temperature fields and orthogonal tests are performed in order to optimize the overall design.The influence of different sets of structural parameters on the cooling performance is examined.It is shown that an optimal scheme exists for which favourable performance can be obtained in terms of hot spot temperature decrease and thermal uniformity improvement.

Heat Transfer Performance and Structural Optimization of a Novel Micro-channel Heat Sink

With the advent of the 5G era,the design of electronic equipment is developing towards thinness,intelligence and multi-function,which requires higher cooling performance of the equipment.Micro-channel heat sink is promising for the heat dissipation of super-thin electronic equipment.In this study,thermal resistance theoretical model of the micro-channel heat sink was first established.Then,fabrication process of the micro-channel heat sink was introduced.Subsequently,heat transfer performance of the fabricated micro-channel heat sink was tested through the developed testing platform.Results show that the developed micro-channel heat sink has more superior heat dissipation performance over conventional metal solid heat sink and it is well suited for high power LEDs application.Moreover,the micro-channel structures in the heat sink were optimized by orthogonal test.Based on the orthogonal optimization,heat dissipation performance of the micro-channel radiator was further improved.

半导体激光器低热阻液冷热沉研究现状与展望

近年来,半导体激光器输出功率持续增加,引发热负载受限问题。热负载使芯片有源区产生温升,进一步影响芯片温度分布,导致半导体激光器(Laser diode,LD)芯片性能逐渐劣化。而对于确定的封装形式,热沉热阻成为控制温升的决定性因素。因此,降低热沉热阻对提升半导体激光器输出能力与光束性质具有重要意义。液冷热沉可以有效降低热阻,本文从液冷热沉材料、液冷热沉结构和液冷冷媒性质三个方面,回顾了近30年LD液冷热沉热阻演变进程,总结了液冷热沉发展过程中热阻的影响因素,进一步探讨了降低热阻的发展方向与应用前景。

基于拓扑优化的车用功率模块Pin-Fin设计方法

集成Pin-Fin散热器可以降低功率模块的结-流热阻,是车用电机控制器热管理的发展趋势。然而,传统参数设计方法无法定量表征Pin-Fin的形貌结构,设计自由度低、设计效果欠佳,难以实现Pin-Fin的热-流协同设计。基于变密度拓扑优化方法,该文提出一种Pin-Fin形貌结构的设计方法,建立Pin-Fin设计的变密度拓扑优化模型,分析模型参数对优化结果和收敛性的影响规律,形成以结-流热阻和冷却液压降为目标的协同优化方法,探索Pin-Fin结构的热-流耦合规律和强化换热方法,得到最优的Pin-Fin散热器形貌结构,搭建变流器实验平台和车用电机控制器样机,对标商业化圆形Pin-Fin结构,以及三角形、菱形和水滴形等其他形貌结构,计及母线电压、负荷电流和冷却液流量的影响,实验结果验证了所提模型方法的可行性和有效性。实验结果表明:基于拓扑优化方法设计的Pin-Fin结构,与传统结构相比可以降低12%的结-流热阻,消除了多芯片结温差异的80%,为车用功率模块和电机控制器研究提供新的思路。