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.

Design and analysis of a high loss density motor cooling system with water cold plates

Aiming at reducing the difficulty of cooling the interior of high-density motors,this study proposed the placement of a water cold plate cooling structure between the axial laminations of the motor stator.The effect of the cooling water flow,thickness of the plate,and motor loss density on the cooling effect of the water cold plate were studied.To compare the cooling performance of water cold plate and outer spiral water jacket cooling structures,a high-speed permanent magnet motor with a high loss density was used to establish two motor models with the two cooling structures.Consequently,the cooling effects of the two models were analyzed using the finite element method under the same loss density,coolant flow,and main dimensions.The results were as follows.(1)The maximum and average temperatures of the water cold plate structure were reduced by 25.5%and 30.5%,respectively,compared to that of the outer spiral water jacket motor;(2)Compared with the outer spiral water jacket structure,the water cold plate structure can reduce the overall mass and volume of the motor.Considering a 100 kW high-speed permanent magnet motor as an example,a water cold plate cooling system was designed,and the temperature distribution is analyzed,with the result indicating that the cooling structure satisfied the cooling requirements of the high loss density motor.

Case-Based Reasoning(CBR) Model for Ultra-Fast Cooling in Plate Mill

New generation thermo-mechanical control process（TMCP） based on ultra-fast cooling is being widely adopted in plate mill to product high-performance steel material at low cost. Ultra-fast cooling system is complex because of optimizing the temperature control error generated by heat transfer mathematical model and process parameters. In order to simplify the system and improve the temperature control precision in ultra-fast cooling process, several existing models of case-based reasoning（CBR） model are reviewed. Combining with ultra-fast cooling process, a developed R5 CBR model is proposed, which mainly improves the case representation, similarity relation and retrieval module. Certainty factor is defined in semantics memory unit of plate case which provides not only internal data reliability but also product performance reliability. Similarity relation is improved by defined power index similarity membership function. Retrieval process is simplified and retrieval efficiency is improved apparently by windmill retrieval algorithm. The proposed CBR model is used for predicting the case of cooling strategy and its capability is superior to traditional process model. In order to perform comprehensive investigations on ultra-fast cooling process, different steel plates are considered for the experiment. The validation experiment and industrial production of proposed CBR model are carried out, which demonstrated that finish cooling temperature（FCT） error is controlled within±25℃ and quality rate of product is more than 97%. The proposed CBR model can simplify ultra-fast cooling system and give quality performance for steel product.

Boundary Layer Distributions and Cooling Rate of Cooling Sloping Plate Process

According to the principle of grain refining and slurry preparation by cooling sloping plate process, the distributions of boundary layers during melt treatment by cooling sloping plate were studied, and mathematic model of cooling rate was established. The calculation value approximately agrees with the experimental result. Laminar flow and turbulent flow exist on sloping plate surface commonly. The thickness of velocity boundary layer and the critical transfer distance from laminar flow to turbulent flow increase with the decrease of initial flow velocity. The thickness of temperature boundary layer increases with the increment of flow distance and the decrease of initial flow velocity. The melt cooling rate and melt thickness have an inverse proportion relationship. The melt cooling rate increases along the plate direction gradually when the initial flow velocity is lower than 1 m/s, the melt cooling rate keeps nearly a constant when the initial flow velocity is 1 m/ s, when the initial flow velocity is higher than 1 m/s, the melt cooling rate decreases gradually. The melt cooling rate of cooling sloping plate process can reach 102-103 K/s and belongs to meta-rapid solidification scope.

Effect of cooling structure on thermal behavior of copper plates of slab continuous casting mold

A three-dimensional finite-element model of slab continuous casting mold was conducted to clarify the effect of cooling structure on thermal behavior of copper plates. The results show that temperature distribution of hot surface is mainly governed by cooling structure and heat-transfer conditions. For hot surface centricity, maximum surface temperature promotions are 30 ℃and 15 ℃ with thickness increments of copper plates of 5 mm and nickel layers of 1 ram, respectively. The surface temperature without nickel layers is depressed by 10 ℃ when the depth increment of water slots is 2 mm and that with nickel layers adjacent to and away from mold outlet is depressed by 7℃ and 5 ℃, respectively. The specific trend of temperature distribution of transverse sections of copper plates is nearly free of cooling structure, but temperature is changed and its law is similar to the corresponding surface temperature.

Influence of plate length and plate cooling rate on solidification and microstructure of A356 alloy produced by oblique plate

A356 alloy melt solidifies partially when it flows down on an oblique plate cooled from bottom by counter flowing water. Columnar dendrites are continuously formed on the plate wall. Because of the forced convection, these dendrites are sheared off into equiaxed/fragmented grains and then washed away continuously by producing semisolid slurry at plate exit. Plate cooling rate provides required extent/amount of solidification whereas plate length enables necessary shear for producing semisolid slurry of desired quality. Slurry obtained is solidified in metal mould to produce semisolid-cast billets of desired microstructure. Furthermore, semisolid-cast billets are also heat-treated to improve surface quality. Microstructures of both semisolid-cast and heat-treated billets are compared. The effects of plate length and plate cooling rate on solidification and microstructure of billets produced by using oblique plate are illustrated. Three different plate lengths（200 mm, 250 mm, 300 mm） associated with three different heat transfer coefficients（1000, 2000 and 2500 W/（m2·K）） are involved. Plate length of 250 mm with heat transfer coefficient of 2000 W/（m2·K） gives fine and globular microstructures and is the optimum as there is absolutely no possibility of sticking of slurry to plate wall.

Thermal modeling and the optimized design of metal plate cooling systems for single concentrator solar cells

A metal plate cooling model for 400~ single concentrator solar cells was established. The effects of the thickness and the radius of the metal plate, and the air environment on the temperature of the solar cells were analyzed in detail. It is shown that the temperature of the solar cells decreased sharply at the beginning, with the increase in the thickness of the metal plate, and then changed more smoothly. When the radius of the metal plate was 4 cm and the thickness increased to 2 mm or thicker, the temperature of the solar cell basically stabilized at about 53℃. Increasing the radius of the metal plate and the convective transfer coefficient made the temperature of the solar cell decrease remarkably. The effects of A1 and Cu as the metal plate material on cooling were analyzed contrastively, and demonstrated the superiority of A1 material for the cooling system. Furthermore, considering cost reduction, space holding and the stress of the system, we optimized the structural design of the metal plate. The simulated results can be referred to the design of the structure for the metal plate. Finally, a method to devise the structure of the metal plate for single concentrator solar cells was given.

Cost reduction of alloying element in high strength steel plate by optimization of controlled cooling technology

Controlled cooling technology is getting more and more attention with the development of thermal-mechanical control process. In the past decade, achieving the given finish cooling temperature was the sole goal for the technology. However ,with the research and development of new steels such as super high strength steel, researchers have in recent years realized the determinate effects that different cooling paths have on the finish cooling temperature and paid more attention to the control of the cooling rate. This paper focuses on not only the optimization of the controlled cooling system with high precision and fast cooling rate, but also the research and development of the high strength steel plate with reduced alloying component.

Computational Film Cooling Effectiveness of Dual Trench Configuration on Flat Plate at Moderate Blowing Ratios

In the present work, computational simulations was made using ANSYS CFX to predict the improvements in film cooling performance with dual trench. Dual-trench confguradon consists of two trenches together, one wider trench and the other is narrow trench that extruded from the wider one. Several blowing ratios in the range （0.5：5） were investigated. The pitch-to-diameter ratio of 2.775 is used. By using the dual trench configuration, the coolant jet impacted the trench wall two times allowing increasing the spreading of coolant laterally in the trench, reducing jet velocity and jet completely covered on the surface. The results indicate that this configuration increased adiabatic effectiveness as blowing ratio increased. The spatially averaged adiabatic effectiveness reached 57.6% for at M= 2. No observed film blow-off at all blowing ratios. The adiabatic film effectiveness of dual trench case outperformed the narrow trench case, laidback fan-shaped hole, fan-shaped hole and cylinder hole at different blowing ratios.

Fluid flow characteristics of single inclined circular jet impingement for ultra-fast cooling

The fluid flow characteristics of the single bunch inclined jet impingement were investigated with different jet flow velocities,nozzle diameters,jet angles and jet-to-target distances for ultra-fast cooling technology.The results show that the peak pressure varying significantly from nearly 0.5 to above 13.4 kPa locates at the stagnation point with different jet diameters,and the radius of impact pressure affected zone is small promoted from 46 to 81 mm in transverse direction,and 50 to 91 mm in longitude direction when the jet flow velocity changes from 5 to 20 m/s.However,the fluid flow velocity is relatively smaller near the stagnation point,and increases gradually along the radius outwards,then declines.There is an obvious anisotropic characteristic that the flow velocity component along the jet direction is about twice of the contrary one where the jet anlge is 60°,jet diameter is 5 mm,jet length is 8 mm and jet height is 50 mm.

Cooling System Design and Thermal Analysis of Modular Stator Hybrid Excitation Synchronous Motor

Hybrid excitation synchronous motor has the advantages of uniform and adjustable electromagnetic field, wide speed range and high power density. It has broad application prospects in new energy electric vehicles, wind power generation and other fields. This paper introduces the basic structure of hybrid excitation motor with modular stator, and analyzes the operation principle of hybrid excitation motor. The cooling structure of the water-cooled plate is designed, and the effects of the thickness of the water-cooled plate and the number of water channels in the water-cooled plate on the heat dissipation capacity of the water-cooled plate are analyzed by theoretical and computational fluid dynamics methods. The effects of different water cooling plate structures on water velocity, pressure drop, water pump power consumption and heat dissipation capacity were compared and analyzed. The influence of different inlet flow velocity on the maximum temperature rise of each part of the motor is analyzed, and the temperature of each part of the motor under the optimal water flow is analyzed. The influence of the traditional spiral water jacket cooling structure and the water-cooled plate cooling structure on the maximum temperature rise of the motor components is compared and analyzed. The results show that the water-cooled plate cooling structure is more suitable for the modular stator motor studied in this paper. Based on the water-cooled plate cooling structure, the air-water composite cooling structure is designed, and the effects of the air-water composite cooling structure and the water-cooled plate cooling structure on the maximum temperature rise of each component of the motor are compared and analyzed. The results show that the maximum temperature rise of each component of the motor is reduced under the air-water composite cooling structure.

Optimization of the Water-Cooled Structure for the Divertor Plates in EAST Based on an Orthogonal Theory

An orthogoual experimental scheme was designed for optimizing a water-cooled structure of the divertor plate. There were three influencing factors： the radius R of the water- cooled pipe, and the pipe spacing L1 and L3. The influence rule of different factors on the cooling effect and thermal stress of the plate were studied, for which the influence rank was respectively R 〉 L1 〉 L3 and L3 〉 R 〉 L1. The highest temperature value decreased when R and L1 increased~ and the maximum thermal stress value dropped when R, L1 and L3 increased. The final optimized results can be summarized as： R equals 6 mm or 7 mm, L1 equals 19 mm, and L3 equals 20 mm. Compared with the initial design, the highest temperature value had a small decline~ and the maximum thermal stress value dropped by 19~ to 24~. So it was not ideal to improve the cooling effect by optimizing the geometry sizes of the water-cooled structure, even worse than increasing the flow speed, but it was very effective for dropping the maximum thermal stress value. The orthogoaal experimental method reduces the number of experiments by 80%, and thus it is feasible and effective to optimize the water-cooled structure of the divertor plate with the orthogonal theory.

Microstructural Transformation and Precipitation of an Ultra-high Strength Steel under Continuous Cooling

We investigated phase transition and precipitation of ultra-high strength steel（UHSS）in a new ＂short process＂ with controlled rolling and controlled cooling.Thermalexpansion test combined with metallographic observation was used to research the continuous cooling transformation（CCT）curve.Moreover,the microstructuraltransformation and precipitation law was revealed by morphologicalobservation and alloying elements by electron probe micro-analyzer（EPMA）.Transmission electron microscopy（TEM）was utilized to analyze the composition and grain orientation of microstructure.The study showed that the measured criticaltransformation temperatures of Ac1 and Ac3 were 746 and 868 ℃,respectively.The CCT curve indicated that the undercooled austenite was transformed into proeutectoid ferrite and bainite with HV 520 in a broad range of cooling rate 0.1^（-1） ℃·s^（-1）.When subjected to a cooling rate of 1 ℃·s^（-1）,the undercooled austenite was divided into small-sized blocks by formed martensite.With further increase of cooling rate,micro-hardness increased dramatically,the microstructure of specimen was mainly lathe bainite（LB）,granular bainite（GB）,lath martensite（LM）and residualaustenite.By diffraction test analysis,it was identified that there was K-S orientation relationship between martensite and austenite for {110}_α//{111}_γ,{111}_α//{101}_γ.EPMA clearly showed that carbon diffused adequately due to staying for a long time at high temperature with a lower cooling rate of 2 ℃·s-1.Phase transition drive force was lower and the residualaustenite existed in the block form of Martensite austenite island（M-A）.With the increase of cooling rate to 10 ℃·s^（-1）,the block residualaustenite reduced,the carbon content of residualaustenite increased and α phase around the residualaustenite formed into a low carbon bainite form.

Air-Water Cooling System for Switch-Mode Power Supplies

The results are presented of an experimental investigation of heat transfer in an air-liquid cooling system for a Switch-Mode Power Supply (SMPS) for TV digital power amplifiers. Since these SMPSs are characterized by high power and high compactness, thereby making the standard cooling techniques difficult to be used, a new cooling system is developed, using water and air as the cooling media. The active components (MOSFETs) are cooled with a liquid cold-plate, the passive ones (condensers, transformers, coils) with an air flow, in turn cooled by the cold-plate. By inserting the cooling system in an experimental tool where it is possible to control the cooling water, measurements are made of temperature in the significant points of the SMPS. The electric efficiency is also measured. The evaluation of the thermal performance of this cooling system is useful in order to limit its maximum operational temperature. The efficacy of the cooling system is demonstrated;the trends of efficiency and power dissipation are evidenced.

异型坯腹板裂纹产生原因与控制

型钢腹板表面裂纹是型钢的主要缺陷之一,为提高轧制成材率,对裂纹产生机理展开研究,通过优化冷却制度、改进结晶器足辊润滑方式,铸坯裂纹大幅减少,H型钢腹板表面质量合格率显著提高。

冷板阻热层对锂电池模组散热均匀性影响

锂电池模组温差过大引发电池间充放电、老化衰减速率不一致,致使其性能变差。为了进一步降低锂电池模组工作温差,提出一种设阻热层的新型冷板,即通过在冷板冷却液入口处与锂电池间增设阻热层增大热阻、抑制锂电池与冷板间热交换改善其散热均匀性。利用新型冷板对锂电池模组3 C放电冷却散热进行建模仿真计算,分析了并行流道、并联蛇形流道以及分叉型流道等3种不同流道冷板增设阻热层对锂电池模组放电散热均匀性影响,以及阻热层材料导热系数、厚度及覆盖面积对锂电池模组冷却散热均匀性影响。结果表明:在3种流道冷板上增设阻热层均能有效降低锂电池模组工作温差。随着阻热层材料导热系数减小,锂电池模组最高温度和温差均先减小后增加。随着阻热层厚度、阻热层覆盖面积增大,锂电池模组工作最高温度和温差均先减小后增大。采用长80 mm、宽80 mm、厚1 mm导热硅胶垫阻热层,分叉型流道冷板冷却锂电池模组3 C放电最高温度和温差降至306.55 K和4.89 K。

增材制造中空风冷板工艺设计与试验

为了验证增材制造技术对复杂中空风冷板的可行性,对中空风冷板模型增材制造工艺性、增材制造打印成型工艺性和粉末选择进行了分析对比。文中优选成熟AlSi10Mg铝合金打印参数完成中空风冷板的成型,并对随炉打印的试样力学性能和表面处理防护性能进行了试验验证。试验结果表明,增材中空风冷板性能可以满足产品设计使用要求。

有轨电车超级电容模组液冷散热仿真分析

超级电容模组因其快速充放电和适应大功率需求的能力被视为有轨电车未来动力电源的发展趋势。然而,在运行和充放电过程中,超级电容模组会产生大量热量,并导致温度在短时间内迅速上升。为解决该问题,本工作提出一种采用微型通道液体冷却的热管理方式,其原理是利用液冷板微型通道内的低温流体对超级电容单体进行冷却,通过改变边界条件确保超级电容模组在不同散热工况下的工作温度始终保持在适宜的范围内。为了比较液冷板性能,本工作设计了三种液冷板微型通道的模型,并使用ANSYS仿真软件对其进行了数值模拟,建立了新型液冷板最高温度预测模型,研究了边界条件对新型液冷板性能的影响。结果表明,design-3液冷板模型具有较好的流动和散热性能,当提高冷却液入口质量流量时,可以有效降低超级电容单体的最大温差和最高温度,改善单体间的均温性。但随着冷却液入口质量流量增至0.35 kg/s后,超级电容单体最高温度降幅逐渐减小,对其散热性能改善有限,提高流量会使热管理系统能量损失增加;当提高冷却液入口温度时,超级电容单体间温差不断减小,但冷却液入口温度对单体的均温性影响不大。