This thesis examines the development of a high efficiency heat pump system using thermoelectric (TE) and reticulated metal foam (RMF) technologies to power a vehicle`s battery thermal management system. The focus is split into two areas: first a review of TE???s sourcing or removing heat, second an examination of compact heat exchanger (HX) design. Five TE suppliers were investigated to understand the performance and limitations of their TE modules. Testing showed the Kyrotherm product to be superior so it was used as a design basis. RMF???s are known to be an effective means to improve the performance of compact heat exchangers, thus HX???s were evaluated with RMF foams compressed to varying densities in order to understand their potential in conjunction with thermoelectric devices. Experimental results showed performance was limited due to adequate bonding, yet still on par with the highest efficiency technologies currently on the market.

Doubling transistor count for every two years in a computer chip, transmitter and receiver (T/R) module of a phased-array antenna that demands higher power with smaller dimensions are all results of miniaturization in electronics packaging. These technologies nowadays depend on improvement of reliable high performance heat sink to perform in narrower volumes. Employing microchannels or open cell metal foam heat sinks are two recently developing promising methods of cooling high heat fluxes. Although recent studies especially on microchannels can give a rough estimate on performances of these two methods, since using metal foams as heat sinks is still needed further studies, a direct experimental comparison of heat exchanger performances of these two techniques is still needed especially for thermal design engineers to decide the method of cooling. For this study, microchannels with channel widths of 300 &micro / m, 420 &micro / m, 500 &micro / m and 900 &micro / m were produced. Also, 92% porous 10, 20 and 40 ppi 6101-T6 open cell aluminum metal foams with compression factors 1,2, and 3 that have the same finned volume of microchannels with exactly same dimensions were used to manufacture heat sinks with method of vacuum brazing. They all have tested under same conditions with volumetric flow rate ranging from 0,167 l/min to 1,33 l/min and 60 W of heat power. Channel height was 4 mm for all heat sinks and distilled water used as cooling fluid. After experiments, pressure drops and thermal resistances were compared with tabulated and graphical forms. Also, the use of metal foam and microchannel heat sinks were highlighted with their advantages and disadvantages for future projects.

Metal foams and wire meshes are open cell structures with low weight and density, high permeability and high thermal conductivity which make them attractive for a wide range of industrial applications involving fluid flow and heat transfer. In this study, the effect of natural convection, radiation and heat transfer enhancement of metal foams and wire meshes of 10 and 40 PPI (pores per inch) heat exchangers were examined and compared for different heat exchanger orientation, coolant flow rate and atmosphere temperature. Thermal spray coating processes were also used in development of a new class of high temperature stainless steel heat exchangers. Stainless steel wire mesh heat exchangers were prototyped by connecting the tube to the wire mesh using wire arc thermal spray coating. Thermal spray coating provided efficient connections between the wire mesh and the tubes’ outer surface, and has potential to replace expensive brazing or other metal connection techniques.

High-power diode lasers (HPDL) are being increasingly used in industrial applications. Deposition of nickel from nickel carbonyl (Ni(CO)4) precursor by laser-induced chemical vapor deposition (CVD) was studied with emphasis on achieving high deposition rates. An HPDL system was used to provide a novel energy source facilitating a simple and compact design of the energy delivery system. Nickel deposits on complex, 3-dimensional polyurethane foam substrates were prepared and characterized. The resulting “nickel foam” represents a novel material of high porosity (>95% by volume) finding uses, among others, in the production of rechargeable battery and fuel cell electrodes and as a specialty high-temperature filtration medium. Deposition rates up to ~19 µm/min were achieved by optimizing the gas precursor flow pattern and energy delivery to the substrate surface using a 480W diode laser. Factors affecting the transition from purely heterogeneous decomposition to a combined hetero- and homogeneous decomposition of nickel carbonyl were studied. High quality, uniform 3-D deposits produced at a rate more than ten times higher than in commercial processes were obtained by careful balance of mass transport (gas flow) and energy delivery (laser power). Cross-flow of the gases through the porous substrate was found to be essential in facilitating mass transport and for obtaining uniform deposits at high rates. When controlling the process in a transient regime (near the onset of homogenous decomposition), unique morphology features formed as part of the deposits, including textured surface with pyramid-shape crystallites, spherical and non-spherical particles and filaments. Operating the laser in a pulsed mode produced smooth, nano-crystalline deposits with sub-100 nm grains. The effect of H2S, a commonly used additive in nickel carbonyl CVD, was studied using both polyurethane and nickel foam substrates. H2S was shown to improve the substrate coverage and deposit uniformity in tests with polyurethane substrate, however, it was found to have no effect in improving the overall deposition rate compared to H2S-free deposition process. Deposition on other selected substrates, such as ultra-fine polymer foam, carbon nanofoam and multi-wall carbon nanotubes, was demonstrated. The HPDL system shows good promise for large-scale industrial application as the cost of HPDL energy continues to decrease.

High-power diode lasers (HPDL) are being increasingly used in industrial applications. Deposition of nickel from nickel carbonyl (Ni(CO)4) precursor by laser-induced chemical vapor deposition (CVD) was studied with emphasis on achieving high deposition rates. An HPDL system was used to provide a novel energy source facilitating a simple and compact design of the energy delivery system. Nickel deposits on complex, 3-dimensional polyurethane foam substrates were prepared and characterized. The resulting “nickel foam” represents a novel material of high porosity (>95% by volume) finding uses, among others, in the production of rechargeable battery and fuel cell electrodes and as a specialty high-temperature filtration medium. Deposition rates up to ~19 µm/min were achieved by optimizing the gas precursor flow pattern and energy delivery to the substrate surface using a 480W diode laser. Factors affecting the transition from purely heterogeneous decomposition to a combined hetero- and homogeneous decomposition of nickel carbonyl were studied. High quality, uniform 3-D deposits produced at a rate more than ten times higher than in commercial processes were obtained by careful balance of mass transport (gas flow) and energy delivery (laser power). Cross-flow of the gases through the porous substrate was found to be essential in facilitating mass transport and for obtaining uniform deposits at high rates. When controlling the process in a transient regime (near the onset of homogenous decomposition), unique morphology features formed as part of the deposits, including textured surface with pyramid-shape crystallites, spherical and non-spherical particles and filaments. Operating the laser in a pulsed mode produced smooth, nano-crystalline deposits with sub-100 nm grains. The effect of H2S, a commonly used additive in nickel carbonyl CVD, was studied using both polyurethane and nickel foam substrates. H2S was shown to improve the substrate coverage and deposit uniformity in tests with polyurethane substrate, however, it was found to have no effect in improving the overall deposition rate compared to H2S-free deposition process. Deposition on other selected substrates, such as ultra-fine polymer foam, carbon nanofoam and multi-wall carbon nanotubes, was demonstrated. The HPDL system shows good promise for large-scale industrial application as the cost of HPDL energy continues to decrease.

An improved steady-state method combining experiment and mathematical modelling has been developed to characterize the scalable convective heat transfer coefficient, hvol [W*m^(-3)*K^(-1)], of uncoated and catalyst-support coated aluminium foam monoliths. The values of hvol were recovered by parameter fitting its model values to experimental temperature data for steady-state air-cooled monoliths under a known heating flux. The model was built with experimentally recovered values of the monolith’s thermal conductivity and fluid permeability along with known values for other physical parameters. The volumetric heat transfer coefficients of 10, 20 and 40 pore-per-inch uncoated aluminium foams were determined to range between 2,700 and 20,000 W*m^(-3)*K^(-1) at channel Reynolds numbers between 85 and 1,700. The presence of a 76 micron thick anodized layer of catalyst support on monolith foams effected a small but significant reduction in the value of hvol. Coating with an anodized layer also reduced the permeabilities of the monoliths to air flow by 4-20%. Knowledge of the scalable parameter, hvol, was used to model a steady-state non-isothermal, non-isobaric heat-coupled methanol reformer. The model shows that changes to the convective transfer coefficient due to coating the monolith with catalyst support may have significant consequences for the thermal profile of the model reactor and for the product yield. / Thesis (Master, Chemical Engineering) -- Queen's University, 2011-12-12 20:11:18.046

Metal foams and wire meshes are open cell structures with low weight and density, high permeability and high thermal conductivity which make them attractive for a wide range of industrial applications involving fluid flow and heat transfer. In this study, the effect of natural convection, radiation and heat transfer enhancement of metal foams and wire meshes of 10 and 40 PPI (pores per inch) heat exchangers were examined and compared for different heat exchanger orientation, coolant flow rate and atmosphere temperature. Thermal spray coating processes were also used in development of a new class of high temperature stainless steel heat exchangers. Stainless steel wire mesh heat exchangers were prototyped by connecting the tube to the wire mesh using wire arc thermal spray coating. Thermal spray coating provided efficient connections between the wire mesh and the tubes’ outer surface, and has potential to replace expensive brazing or other metal connection techniques.

This report details an approach to using metal foam heat exchangers inside an integrated thermal management system on a variable cycle engine. The propulsion system of interest is a variable cycle engine with an auxiliary, variable flow rate fan. The feasibility of utilizing an open-celled metallic foam heat exchanger in the ducting between the constant and variable-fans on this variable cycle engine to cool the avionics was explored using an experimental approach. Two heat exchangers, 6.3 inch width by 6.3 inch length by 0.5 inch thickness, were constructed from 20 and 40 pores per inch (PPI) metal foam and tested. Both were constructed using 6061-T6 aluminum open-cell metal foam with a relative density of 8% and brazed using 4047 aluminum braze to 0.02 inch thick sheet metal made of 6061-T6 aluminum. Both models were subjected to internal forced convection using heated air with flow rates of 4, 8, 12, 16, and 20 standard cubic feet per minute (SCFM). They were also subjected to external forced convection using blowers to supply cooling air to simulate the variable cycle engine’s fans. One duct was supplied with a constant 34 ft/s cooling flow, while the other cooling flow velocity was varied between 0% and 100% of this 34 ft/s, in 25% increments. The temperature and pressure of the flow internal to the metal foam, as well as the heat exchanger external surface and cold flow temperatures, were recorded. A hot-flow Reynolds number range of 1,300 to 6,400 was tested. Results showed expected trends for the hydraulic performance of both heat exchangers. The form factors were 50.4 and 54.8 ft^-1 and the permeabilities were 9.11E-7 and 6.32E-7 ft^2 for the 20 and 40 PPI heat exchangers, respectively. Due to a defect on one side of the 40 PPI heat exchanger, the thermal results are based only on the 20 PPI heat exchanger. While the present study examines a different metal foam heat transfer configuration than most other studies, the metal foam Nusselt numbers were comparable to past studies. In addition, the pumping power required was not excessive and would allow the thermal management system to be realized without an unreasonable energy input. Therefore, a metal foam heat exchanger integrated within the ducting of a variable cycle engine is deemed feasible. The pumping power and thermal resistance were used to create a performance predicting model of the 20 PPI heat exchanger. From this model, the optimized 20 PPI heat exchanger has a hot-flow rate of 10.5 SCFM. The resulting pumping power and thermal resistance are estimated to be 6.7 BTU/hr and 0.036 °R/(BTU/hr), respectively.

Metal foam is a relatively new and potentially revolutionary material that allows for components to be replaced with elements capable of large energy dissipation, or components to be stiffened with elements which will generate significant supplementary energy dissipation when buckling occurs. Metal foams provide a means to explore reconfiguring steel structures to mitigate cross-section buckling in many cases and dramatically increase energy dissipation in all cases. The microstructure of metal foams consists of solid and void phases. These voids have random shape and size. Therefore, randomness ,which is introduced into metal foams during the manufacturing processes, creating more uncertainty in the behavior of metal foams compared to solid steel. Therefore, studying uncertainty in the performance metrics of structures which have metal foams is more crucial than for conventional structures. Therefore, in this study, structural application of metal foams considering material and geometrical uncertainty is presented. This study applies the Sobol' decomposition of a function of many random variables to different problem in structural mechanics. First, the Sobol' decomposition itself is reviewed and extended to cover the case in which the input random variables have Gaussian distribution. Then two examples are given for a polynomial function of 3 random variables and the collapse load of a two story frame. In the structural example, the Sobol' decomposition is used to decompose the variance of the response, the collapse load, into contributions from the individual input variables. This decomposition reveals the relative importance of the individual member yield stresses in determining the collapse load of the frame. In applying the Sobol' decomposition to this structural problem the following issues are addressed: calculation of the components of the Sobol' decomposition by Monte Carlo simulation; the effect of input distribution on the Sobol' decomposition; convergence of estimates of the Sobol' decomposition with sample size using various sampling schemes; the possibility of model reduction guided by the results of the Sobol' decomposition. For the rest of the study the different structural applications of metal foam is investigated. In the first application, it is shown that metal foams have the potential to serve as hysteric dampers in the braces of braced building frames. Using metal foams in the structural braces decreases different dynamic responses such as roof drift, base shear and maximum moment in the columns. Optimum metal foam strengths are different for different earthquakes. In order to use metal foam in the structural braces, metal foams need to have stable cyclic response which might be achievable for metal foams with high relative density. The second application is to improve strength and ductility of a steel tube by filling it with steel foam. Steel tube beams and columns are able to provide significant strength for structures. They have an efficient shape with large second moment of inertia which leads to light elements with high bending strength. Steel foams with high strength to weight ratio are used to fill the steel tube to improves its mechanical behavior. The linear eigenvalue and plastic collapse finite element (FE) analysis are performed on steel foam filled tube under pure compression and three point bending simulation. It is shown that foam improves the maximum strength and the ability of energy absorption of the steel tubes significantly. Different configurations with different volume of steel foam and composite behavior are investigated. It is demonstrated that there are some optimum configurations with more efficient behavior. If composite action between steel foam and steel increases, the strength of the element will improve due to the change of the failure mode from local buckling to yielding. Moreover, the Sobol' decomposition is used to investigate uncertainty in the strength and ductility of the composite tube, including the sensitivity of the strength to input parameters such as the foam density, tube wall thickness, steel properties etc. Monte Carlo simulation is performed on aluminum foam filled tubes under three point bending conditions. The simulation method is nonlinear finite element analysis. Results show that the steel foam properties have a greater effect on ductility of the steel foam filled tube than its strength. Moreover, flexural strength is more sensitive to steel properties than to aluminum foam properties. Finally, the properties of hypothetical structural steel foam C-channels foamed are investigated via simulations. In thin-walled structural members, stability of the walls is the primary driver of structural limit states. Moreover, having a light weight is one of the main advantages of the thin-walled structural members. Therefore, thin-walled structural members made of steel foam exhibit improved strength while maintaining their low weight. Linear eigenvalue, finite strip method (FSM) and plastic collapse FE analysis is used to evaluate the strength and ductility of steel foam C-channels under uniform compression and bending. It is found that replacing steel walls of the C-channel with steel foam walls increases the local buckling resistance and decreases the global buckling resistance of the C-channel. By using the Sobol' decomposition, an optimum configuration for the variable density steel foam C-channel can be found. For high relative density, replacing solid steel of the lips and flange elements with steel foam increases the buckling strength. On the other hand, for low relative density replacing solid steel of the lips and flange elements with steel foam deceases the buckling strength. Moreover, it is shown that buckling strength of the steel foam C-channel is sensitive to the second order Sobol' indices. In summary, it is shown in this research that the metal foams have a great potential to improve different types of structural responses, and there are many promising application for metal foam in civil structures.

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