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.

Directional solidification casting technology of heavy-duty gas turbine blade with liquid metal cooling(LMC) process

In this work, some important factors such as ceramic shell strength, heat preservation temperature, standing time and withdrawal rate, which influence the formability of directionally solidified large-size blades of heavy-duty gas turbine with the liquid metal cooling(LMC) process, were studied through the method of microstructure analysis combining. The results show that the ceramic shell with medium strength(the high temperature flexural strength is 8 MPa, the flexural strength after thermal shock resistance is 12 MPa and the residual flexural strength is 20 MPa) can prevent the rupture and runout of the blade. The appropriate temperature(1,520 ℃ for upper region and 1,500 ℃ for lower region) of the heating furnace can eliminate the wide-angle grain boundary, the deviation of grain and the run-out caused by the shell crack. The holding time after pouring(3-5 min) can promote the growth of competitive grains and avoid a great deviation of columnar grains along the crystal orientation <001>, resulting in a straight and uniform grain structure. In addition, to avoid the formation of wrinkles and to ensure a smooth blade surface, the withdrawal rate should be no greater than the growth rate of grain. It is also found that the dendritic space of the blade decreases with the rise of solidification rate, and increases with the enlarging distance between the solidification position and the chill plate.

Development of liquid-nitrogen-cooling friction stir spot welding for AZ31 magnesium alloy joints

A liquid-nitrogen-cooling friction stir spot welding(C-FSSW) technology was developed for welding AZ31 magnesium alloy sheets. The liquid-nitrogen cooling degraded the deformability of the welded materials such that the width of interfacial cracks increased with increasing cooling time. The grain size of the stirred zone(SZ) and the heat-affected zone(HAZ) of the C-FSSW-welded joints decreased, whereas that of the thermomechanically affected zone(TMAZ) increased with increasing cooling time. The maximum tensile shear load of the C-FSSW-welded joints welded with a cooling time of 5 or 7 s was larger than that of the friction stir spot welding(FSSW)-welded joint, and the tensile shear load decreased with increasing cooling time. The microhardness of the C-FSSW-welded joints was greater than that of the FSSW-welded joint. Moreover, the microhardness of the SZ and the HAZ of the C-FSSW-welded joints increased, whereas that of the TMAZ decreased, with increasing cooling time.

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.

STABILITY OF MICROSTRUCTURES DURING COOLING PROCESSES OF Al LIQUID METAL

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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%.

A LN2-based cooling system for a next-generation liquid xenon dark matter detector

In recent years, cooling technology for liquid xenon(LXe) detectors has advanced driven by the development of dark matter(DM) detectors with target mass in the 100–1000 kg range. The next generation of DM detectors based on LXe will be in the 50,000 kg(50 t)range requiring more than 1 k W of cooling power. Most of the prior cooling methods become impractical at this level.For cooling a 50 t scale LXe detector, a method is proposed in which liquid nitrogen(LN2) in a small local reservoir cools the xenon gas via a cold finger. The cold finger incorporates a heating unit to provide temperature regulation. The proposed cooling method is simple, reliable, and suitable for the required long-term operation for a rare event search. The device can be easily integrated into present cooling systems, for example the ‘‘Cooling Bus’ ’employed for the Panda X I and II experiments. It is still possible to cool indirectly with no part of the cooling or temperature control system getting in direct contact with the clean xenon in the detector. Also, the cooling device can be mounted at a large distance, i.e., the detector is cooled remotely from a distance of 5–10 m. The method was tested in a laboratory setup at Columbia University to carry out different measurements with a small LXe detector and behaved exactly as predicted.

Liquid phase separation of Cu-Cr alloys during rapid cooling

The ribbons of Cu-Cr alloys with high Cr content (15%- 35%, mass fraction) were prepared by rapid solidification. The microstructures of solidified samples were analyzed by scanning electron microscopy and transmission electron microscopy. The results reveal that a representative liquid phase separation microstructures are observed in Cu75Cr25 ribbons solidified at a cooling rate of about 104K/s. The liquid phase separation is not restrained when the cooling rate is enhanced to about 107K/s. However, the size of Cr particles solidified from Cr-rich liquid or Cr-rich regions in alloy melts could be refined by increasing the cooling rates. The size of Cr particles increases with increasing Cr contents when the ribbons contain 15% to 35%Cr.

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.

Air/CO2 cooling garment: Description and benefits of use for subjects exposed to a hot and humid climate during physical activities

The severity of the hot and humid conditions to which miners are exposed increases as the depth of the work site increases.This can cause heat stress that can greatly affect the health and safety of workers.To resolve this,a cooling garment has been developed that uses an atmospheric discharge of liquid CO2 to create a cool microclimate with an average temperature of 12.5(±0.4)℃ beneath the garment.To evaluate the garment's cooling efficiency,19 male subjects participated in an experimental procedure.The two modes,cooling on and off,were compared.Significant physiological differences were found between the two modes after minute 27(p<0.05)until the end of the recovery phase for the heart rate(maximum difference of 10 beats per minute)and the internal body temperature(maximum difference of 0.33℃).It was found that the modes also affected the subjects'perceptions.The ON-mode was associated with better well-being and thermal comfort,and reduced humidity sensation.Perceptions of exertion were lower in the ON-mode condition from minute 2.The findings provide strong evidence of the ability of this cooling garment to reduce heat stress in hot and humid conditions similar to those encountered in deep mines.

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.

Superelastic Radiative Cooling Metafabric for Comfortable Epidermal Electrophysiological Monitoring

Epidermal electronics with superb passive-cooling capabilities are of great value for both daytime outdoor dressing comfort and low-carbon economy. Herein, a multifunctional and skinattachable electronic is rationally developed on a porous all-elastomer metafabric for efficient passive daytime radiative cooling(PDRC) and human electrophysiological monitoring. The cooling characteristics are realized through the homogeneous impregnation of polytetrafluoroethylene microparticles in the styrene–ethylene–butylene–styrene fibers, and the rational regulation of microporosity in SEBS/PTFE metafabrics, thus synergistically backscatter ultraviolet–visible–near-infrared light(maximum reflectance over 98.0%) to minimize heat absorption while efficiently emit human-body midinfrared radiation to the sky. As a result, the developed PDRC metafabric achieves approximately 17℃ cooling effects in an outdoor daytime environment and completely retains its passive cooling performance even under 50% stretching. Further, high-fidelity electrophysiological monitoring capability is also implemented in the breathable and skin-conformal metafabric through liquid metal printing, enabling the accurate acquisition of human electrocardiograph, surface electromyogram, and electroencephalograph signals for comfortable and lengthy health regulation. Hence, the fabricated superelastic PDRC metafabric opens a new avenue for the development of body-comfortable electronics and low-carbon wearing technologies.

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.

Waste heat water pumping model with direct contact cooling

The performance of a patented water pumping model with steam-air power was presented, which operates automatically by direct contact cooling method. The main objective was to study feasibility of a pumping model for underground water. In this model, a heater installed within the heat tank represented sources of waste heat as energy input for finding appropriate conditions of the 10 L pump model. The system operation had five stages： heating, pumping, vapor flow, cooling, and water suction. The overall water heads of 3, 4.5, 6 and 7.5 m were tested. At the same time, it was found that the pump with 50% air volume is sufficient for pumping water to a desired level. In the experiment, the temperatures in the heating and pumping stages were 100-103 ℃and 80-90 ℃, respectively. The pressure in the pumping stage was 12-18 kPa, and the pressure in the suction stage was about-80 kPa, sufficient for the best performance. It could pump 170 L of water at a 2 m suction head, 120 L at a 3.5 m suction head, 100 L at a 5 m suction head, and 65 L at a 6.5 m suction head in 2 h. A mathematical model for larger pumps was also presented, which operates nearly the same as the present system. Economic analysis of the 10 L pump was also included.

Gas Absorption and Mass Transfer in a Pore-Array Intensified Tube-in-Tube Microchannel

A pore-array intensified tube-in-tube microchannel(PA-TMC),which is characterized by high throughput and low pressure drop,was developed as a gas–liquid contactor.The sulfite oxidation method was used to determine the oxygen efficiency(φ)and volumetric mass transfer coefficient(k_(L)a)of PA-TMC,and the mass transfer amount per unit energy(ε)was calculated by using the pressure drop.The effects of structural and operating parameters were investigated systematically,and the twophase flow behavior was monitored by using a charge-coupled device imaging system.The results indicated that the gas absorption efficiency and mass transfer performance of the PA-TMC were improved with increasing pore number,flow rate,and number of helical coil turns and decreasing pore size,row number,annular size,annular length,and surface tension.Theφ,εand k La of PA-TMC could reach 31.3%,1.73×10^(-4) mol/J,and 7.0 s-1,respectively.The Sherwood number was correlated with the investigated parameters to guide the design of PA-TMC in gas absorption and mass transfer processes.

Effect of droplet characteristics on liquid-phase distribution in spray zone of internal mixing air-mist nozzle

In continuous casting production,droplet characteristics are important parameters for evaluating the nozzle atomization quality,and have a significant impact on the secondary cooling effect and the slab quality.In order to study the behavior of atomized droplets after reaching the slab surface and to optimize the spray cooling effect,the influence of droplet diameter and droplet velocity on the migration behavior of droplets in the secondary cooling zone was analyzed by FLUENT software.Results show that the droplets in the spray zone and on the slab surface are mainly concentrated in the center,thus,the liquid volume fraction in the center is higher than that of either side.As the droplet diameter increases,the region of high liquid volume fraction on the slab surface becomes wider,and the liquid phase distribution in the slab width direction becomes uneven.Although increasing the droplet velocity at the nozzle exit has little effect on droplet diffusion in the spray zone,the distribution becomes more uneven due to more liquid reaches the slab surface per unit time.A prediction formula of the maximum water flow rate on the slab surface for specific droplet characteristics was proposed based on dimensionless analysis and validated by simulated data.A nozzle spacing of 210 mm was recommended under the working conditions in this study,which ensures effective coverage of the spray water over the slab surface and enhances the distribution uniformity of water flow rate in the transverse direction.