Numerical and Experimental Study of a Novel Additively Manufactured Metal-Polymer Composite Heat-Exchanger for Liquid Cooling Electronics

Gargi Kailkhura, Raphael Kahat Mandel, Amir Shooshtari and Michael Ohadi
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Gargi Kailkhura: Advanced Heat Exchangers and Process Intensification (AHXPI) Laboratory, Department of Mechanical Engineering, University of Maryland, College Park, MD 20742, USA
Raphael Kahat Mandel: Advanced Heat Exchangers and Process Intensification (AHXPI) Laboratory, Department of Mechanical Engineering, University of Maryland, College Park, MD 20742, USA
Amir Shooshtari: Advanced Heat Exchangers and Process Intensification (AHXPI) Laboratory, Department of Mechanical Engineering, University of Maryland, College Park, MD 20742, USA
Michael Ohadi: Advanced Heat Exchangers and Process Intensification (AHXPI) Laboratory, Department of Mechanical Engineering, University of Maryland, College Park, MD 20742, USA

Energies, 2022, vol. 15, issue 2, 1-22

Abstract: In order to meet increasing power-dissipation requirements of the electronics industry, compact, low-cost, and lightweight heat exchangers (HXs) are desired. With proper design, materials, and manufacture, polymer composite heat exchangers could meet these requirements. This paper presents a novel crossflow air-to-water, low-cost, and lightweight metal-polymer composite HX. This HX, which is entirely additively manufactured, utilizes a novel cross-media approach that provides direct heat exchange between air and liquid sides by using connecting fins. A robust numerical model was developed, which includes the dimensional effects of additive manufacturing. The study consists of a simplified 3D CFD model based on ellipsoidal-shaped staggered tube banks for the laminar range. It then uses an analytical approach to compute entire HX performance. The model is validated experimentally within 8% for thermal performance, 12% for air-side impedance, and 18% for water-side impedance. Finally, HX is compared with a conventional CPU radiator and performs within 10% of the conventional unit for reasonable flow rates and pressure-drop ranges. Moreover, HX also provides added design and cost advantages over the conventional unit, which makes the HX a potential candidate for electronic cooling applications.

Keywords: air-to-water HX; cross-media; additive manufacturing; experiment; 3D CFD modeling; ellipsoidal tube banks (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2022
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (2)

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