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Net Shape Fins for Compact Heat Exchanger Produced by Cold Spray

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Abstract

This work explores the manufacturability of pyramidal fin arrays produced using the cold spray process. Near-net shaped pyramidal fin arrays of various sizes and fin densities were manufactured using masks made of commercially available steel wire mesh. The feedstock powders used to produce the fins are characterized using scanning electron microscopy. Obstruction of the masks was investigated. The standoff distances between the substrate, mesh, and nozzle were empirically determined. Fin array characterization was performed using digital microscopy. The fin arrays’ heat transfer performance was assessed experimentally for a range of Reynolds number relevant to the application sought. The fins produced using the cold spray process outperform traditional straight (rectangular) fins at the same fin density and it is hypothesized that this is due to increased fluid mixing and turbulence.

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Abbreviations

∆T 1 :

Inlet temperature difference (K)

∆T 2 :

Outlet temperature difference (K)

∆T lm :

Log-mean temperature difference (K)

ηf :

Individual fin efficiency

ηo :

Overall fin efficiency

θ:

Spray angle (°)

μ:

Dynamic viscosity (Pa s)

ρ:

Fluid density (kg/m3)

A f :

Fin heat transfer area (m2)

A flow :

Net flow area (m2)

A tot :

Total heat transfer area (m2)

A u :

Unfinned heat transfer area (m2)

B :

Base fin length (m)

Cp:

Fluid specific heat capacity (kJ/(kg K))

D :

Base diameter (m)

d h :

Hydraulic diameter (m)

FD:

Fin density (fin/m)

H :

Channel height (m)

h :

Convective heat transfer coefficient (W/(m2 K))

I 1 :

Bessel function of order one

I 2 :

Bessel function of order two

j :

Colburn factor

k f :

Fluid thermal conductivity (W/(m K))

k m :

Fin material thermal conductivity (W/(m K))

L :

Sample length (m)

\( \dot{m} \) :

Mass flow rate (kg/s)

m :

Fin heat transfer parameter (m−1)

Nu D :

Nusselt number based on hydraulic diameter

N f :

Number of fins

P flow :

Flow perimeter (m)

Pr :

Prandtl Number

q :

Heat flux (W/m2)

Re D :

Reynolds number based on hydraulic diameter

R eq :

Equivalent thermal resistance (K/W)

S :

Space between fin edges (m)

T in :

Inlet fluid temperature (K)

T out :

Outlet fluid temperature (K)

UA:

Thermal conductance (W/K)

V :

Fluid velocity (m/s)

W :

Channel width (m)

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Acknowledgments

The authors would like to thank Dr. Mohammed Yandouzi of the University of Ottawa Cold Spray Laboratory for his help obtaining the SEM micrographs shown in this publication. Acknowledgements are due to the MITACS Accelerate program for its financial support of this project.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Ottawa, Ottawa, ON, Canada

    Yannick Cormier, Philippe Dupuis & Bertrand Jodoin

  2. Brayton Energy Canada, Aylmer, QC, Canada

    Antoine Corbeil

Authors
  1. Yannick Cormier
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  2. Philippe Dupuis
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  3. Bertrand Jodoin
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  4. Antoine Corbeil
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Corresponding author

Correspondence to Yannick Cormier.

Additional information

This article is from a presentation at the 2013 International Thermal Spray Conference, held May 13-15, 2013, in Busan, South Korea, and has been expanded from the original presentation.

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Cormier, Y., Dupuis, P., Jodoin, B. et al. Net Shape Fins for Compact Heat Exchanger Produced by Cold Spray. J Therm Spray Tech 22, 1210–1221 (2013). https://doi.org/10.1007/s11666-013-9968-x

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