Pyramidal Fin Arrays Performance Using Streamwise Anisotropic Materials by Cold Spray Additive Manufacturing
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Yannick Cormier, Philippe Dupuis, Bertrand Jodoin, and Antoine Corbeil (Submitted April 16, 2015; in revised form May 28, 2015) This work evaluates the thermal and hydrodynamic performance of pyramidal fin arrays produced using cold spray as an additive manufacturing process. Near-net-shaped pyramidal fin arrays of pure aluminum, pure nickel, and stainless steel 304 were manufactured. Fin array characterization such as fin porosity level and surface roughness evaluation was performed. The thermal conductivities of the three different coating materials were measured by laser flash analysis. The results obtained show a lower thermal efficiency for stainless steel 304, whereas the performances of the aluminum and nickel fin arrays are similar. This result is explained by looking closely at the fin and substrate roughness induced by the cold gas dynamic additive manufacturing process. The multi-material fin array sample has a better thermal efficiency than stainless steel 304. The work demonstrates the potential of the process to produce streamwise anisotropic fin arrays as well as the benefits of such arrays.
Keywords
additive manufacturing, cold spray, heat transfer, pin fin array, thermal conductivity
1. Introduction Research focusing on the enhancement of heat exchanger performance has become a priority in areas such as gas turbine development, electronic cooling, and power generation (Ref 1–4). Indeed, heat exchangers have become common components in various engineering disciplines due to the importance and the challenges associated with thermal management. Some of the most widely used heat exchanger designs rely on fin arrays as heat transfer enhancing surfaces to be able to minimize the size and weight of such components for a given heat exchange rate (Ref 1, 4). Enhancing thermal conductance of fin arrays while decreasing the size of heat exchangers is also especially important for the aerospace and automotive industries, for which the weight and volume of components are important factors. To increase the ratio of heat transfer area per unit volume, fins have tended to become longer and slimmer
This article is an invited paper selected from presentations at the 2015 International Thermal Spray Conference, held May 11–14, 2015, in Long Beach, California, USA, and has been expanded from the original presentation. Yannick Cormier, Philippe Dupuis, and Bertrand Jodoin, Department of Mechanical Engineering, University of Ottawa, Ottawa, Canada; and Antoine Corbeil, Brayton Energy Canada, Gatineau, Canada. Contact e-mail: [email protected].
Journal of Thermal Spray Technology
combined with a higher fin density (amount of fins per unit base area). This densification of the fin arrays has some practical limitations based on the manufacturing techniques used to produce these features. Extrusion and machining have typically been used to produce both continuous fin and pin fin arrays, respectively (Ref 5). Casting has also been used as an alternative production method for these arrays (Ref 5). All these man
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