Evaluation of the effects of the metal foams geometrical features on thermal and fluid-dynamical behavior in forced conv
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ORIGINAL ARTICLE
Evaluation of the effects of the metal foams geometrical features on thermal and fluid-dynamical behavior in forced convection D. Almonti 1 & G. Baiocco 2 & Emanuele Mingione 3
&
N. Ucciardello 1
Received: 30 July 2020 / Accepted: 14 September 2020 / Published online: 8 October 2020 # The Author(s) 2020
Abstract Metal foams are a material, featuring interesting characteristics for the aeronautical and automotive fields because of their low specific weight, high thermal properties, and mechanical performances. In particular, this paper deals with thermal and fluid dynamic study of 24 open-cell aluminum EN43500 (AlSi10MnMg) metal foams produced by indirect additive manufacturing (IAM), combining 3D printing and metal casting to obtain a controllable morphology. A study of foam behavior function of the morphological features (pores per inch (PPI), branch thickness (r), and edges morphology (smooth-regular)) was performed. The samples produced were heated by radiation and tested in an open wind circuit gallery to measure the fluid dynamic properties such as pressure drop (Δp), inertial coefficient ( f ), and permeability (k), in an air forced convection flow. The thermal characterization was performed evaluating both the theoretical (kth) and effective (keff) thermal conductivity of the foams. Also, the global heat transfer coefficient (HTCglobal) was evaluated with different airflow rates. Analysis of variance (ANoVA) was performed to figure out which geometrical parameters are significant during both thermal and fluid dynamic processes. The results obtained show how the controllable foam morphology can affect the involved parameters, leading to an ad hoc design for industrial applications that require high thermo-fluid-dynamical performances. Keywords Metal foams . Analysis of variance . Investment casting . Global heat transfer . Indirect additive manufacturing
1 Introduction Metal foams are a class of cellular materials with cells randomly oriented and homogeneous in size and shape. Due to their high surface area per unit volume, many authors discussed the properties for a large number of engineering applications, such as condenser for geothermal power plants, groundwater pollution and filters, chemical reactors, vibration control, and energy management, combustion chambers,
* Emanuele Mingione [email protected] 1
Department of Enterprise Engineering Mario Lucertini, University of Rome: “Tor Vergata”, Via del Politecnico 1, 00133 Rome, Italy
2
Department of Engineering, University “Roma Tre”, Via Vito Volterra 62, 00146 Rome, Italy
3
Department of Engineering, University of Campania “Luigi Vanvitelli”, Via Roma, 9, 81031 Aversa, Italy
strain isolation, catalytic beds, air conditioning, and refrigeration systems [1–7]. Because of the high surface-volume ratio, the open-cell cellular materials offer excellent performance in heat exchange, due to their unusual structure that enhances the flow mixing ability and the production of turbulence in the fluid flow when passing through
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