By focusing on the cooling requirement of high power LED, the study aims to explore the spray cooling method and analyze its cooling performance. The ultrasonic micro-nozzle plate made of piezoelectric ceramic material was used in this experiment in order to establish a spray cooling system. The nozzle plate array (3 ¡Ñ 2) was used to carry out a cooling test for 24 LEDs with high power (6 ¡Ñ 4). Three different watts (1 W, 3 W, 5 W) of LED were tested, the total input power was 24W, 72W and 120 W, respectively, and the working medium was DI water. The goal is to understand the variance in performance caused by nozzle plates of different nozzle diameters (dj = 7, 35 £gm) in varied nozzle distances (z = 10, 20, 30, 40, 50 mm). The experiment used thermocouples to measure the slug temperature of LED. By applying thermal resistnace to the LED to calculate its chip temperature, and using micrometer resolution particle image velocimetry (£gPIV) to observe the spray flowfield inside the LED chamber, this study analyzes the influence of flowfield change on cooling performance.

This study aims to explore the use of an ultrasonic micro-nozzle plate, made of piezoelectric ceramic material, as a core material to establish a set of spray cooling system for high power LED. The system uses a single nozzle plate to implement a cooling test for 4 high power LEDs (2 ¡Ñ 2). The total input power was 4 W, 12 W and 20 W, and working medium was DI water. In order to understand the performance variance introduced by utilizing nozzle plates with differing nozzle diameters (dj = 7, 35 £gm) across various nozzle exit to test distance (z = 10, 20, 30, 40, 50 mm). By using micrometer resolution particle image velocimetry (£gPIV) to observe the spray flowfield inside the chamber, and using thermocouples to measure the temperature of LED slug and thermal resistance was used to calculate the LED junction temperature , Tj, for analyzing the influence of flowfield change spread in chamber on its cooling performance. The possibility of an LED spray cooling system is also explored.

The aim of this study is to design and build a miniature spray cooling system, in which the manufactured and adopted chamber, pump and heat exchanger are smaller than the conventional ones. An experiment was conducted to explore the cooling performance of the spray cooling system after its size has been minimized. In the experiment, copper was used to make the heated surface and different working media, such as DI water, as nanofludics with silver and multi-walled carbon nanotubes powder were sprayed on the heated surface to enhance the heat dissipation efficiency of the system. The experiment in this study was set according to two conditions: transient and steady state, with Weber number as the main parameter, to observe the boiling phenomenon of different working media on heated surface and to record the temperature changes of the heated surface. The results were shown in boiling curve and cooling curve. The ultimate goal of this study was to obtain a better understanding of the cooling performance of the miniature spray cooling system in order to apply it to micro-electronic cooling devices, thereby solving the problem of the sharp increase in heating power per unit area on electronic components.

Spray cooling has proven to be efficient in managing thermal load in high power applications. Reliability of electronic products relies on the thermal management and understanding of heat transfer mechanisms including those related to spray cooling. However, to date, several of the key heat transfer mechanisms are still not well understood. An alternative approach for improving the heat transfer performance is to change the film dynamics through surface modification. The main goal of this study is to understand the effects of nano-scale features on flat heater surfaces subjected to spray cooling and to determine the major factors in droplet impingement cooling to estimate their effects in the spray cooling system. Single droplet stream and simultaneous triple droplet stream with two different stream spacings (500 μm and 2000 μm), experiments have been performed to understand the droplet-surface interactions relevant to spray cooling systems. Experiments have been conducted on nano-structured surfaces as well as on flat (smooth) surfaces. It is observed that nano-structured surfaces result in lower minimum wall temperatures, better heat transfer performance, and more uniform temperature distribution. A new variable, effective thermal diameter (de), was defined based on the radial temperature profiles inside the impact zone to quantify the effects of the nano-structured surface in droplet cooling. Results indicate that larger effective cooling area can be achieved using nano-structured surface in the single droplet stream experiments. In triple stream experiments, nano-structured surface also showed an enhanced heat transfer. In single stream experiments, larger outer ring structures (i.e. larger outer diameters) in the impact crater were observed on the nano-structured surfaces which can be used to explain enhanced heat transfer performance. Smaller stream spacing in triple stream experiments reveal that the outer ring structure is disrupted resulting in lower heat transfer. Lower static contact angle on the nano-structured surface has been observed, which implies that changes in surface properties result in enhanced film dynamics and better heat transfer behavior. The results and conclusions of this study should be useful for understanding the physics of spray cooling and in the design of better spray cooling systems.

Title from PDF of title page. / Document formatted into pages; contains 230 pages. / Thesis (M.S.M.E.)--University of South Florida, 2003. / Includes bibliographical references. / Text (Electronic thesis) in PDF format. / ABSTRACT: A conical nozzle with two separate inlets within its top plate is analyzed. One of the inlets is in the center of the top plate, which is free to rotate, whereas the other inlet is positioned away from the center. The fluid entering through the outer inlet slot causes the top plate of the nozzle to spin. Several fluids including FC-77, FC-72, FC-87, and Methanol running at different flow rates were investigated to observe the effect that their particular properties have on the geometry of the fluid's free surface exiting the nozzle. Another variation performed was the geometry of the nozzle. The outer inlet slot was positioned at various radial distances along the top plate. For this nozzle, the top plate remained stationary and swirling was introduced to the fluid at the inlets. It was observed that the faster flow rates caused an increase in the free surface height and cone angle. / ABSTRACT: For the various radial locations of the outer inlet slot, it was noted that a position at approximately 75% of the nozzle radius produced the largest free surface height. The largest cone angle was produced when the outer inlet slot was positioned at the edge of the nozzle top plate. Another factor that increased the radial height and cone angle of the free surface was the working fluid used in the study. A larger Reynolds number produced a larger cone angle and larger free surface height (while a smaller Reynolds number produced a less significant cone angle and free surface height). / System requirements: World Wide Web browser and PDF reader. / Mode of access: World Wide Web.

The research performed in this work investigated evaporative spray cooling systems using water near a 45 degree bends in gas turbine exhaust piping systems. Both experimental data and numerical data were generated with the goal of evaluating the ability of Fluent 6.3.26 to predict the performance of these systems for the purpose of design using only modest computational resources. Three cases were investigated in this research: single phase exhaust flow with no water injection, injecting water before the bend and injecting water after the bend. Various probes were used to measure dry bulb temperature, total pressure and water mass flux of the two phase flow at the exit of the pipe. Seven hole probes and pitot static probes were used to measure single phase flow properties. Numerical simulations were performed using mass flow boundary conditions which were generated from experimental results. A turbulence model was selected for the simulations based on comparisons of single phase simulations with experimental data and convergence ability. Using Fluent’s discrete phase model, different wall boundary conditions for the discrete phase were used in order to find the model which would best match the evaporation rates of the experimental data. Mass flux values through the exit plane of the pipe were found to be the most reliable of all the two phase data collected. Results from numerical simulations revealed the shortcomings of the available discrete phase wall boundary conditions to accurately predict the interaction of the liquid phase with the wall. Experimental results for both cases showed extensive areas of the wall which had liquid film layers running down the length of the pipe. Simulations resulted in particles either failing to impact the wall and create a liquid film, or creating a liquid film which was much smaller than the film present in experimental results. This led to 8% and 15% discrepancy in evaporation amounts between numerical and experimental results for water injection upstream and downstream of the bend respectively. Under-prediction of areas wetted with a wall film in the simulations also led to gross over predictions of wall temperature in numerical results. / Thesis (Master, Mechanical and Materials Engineering) -- Queen's University, 2014-01-02 11:02:00.955

This study aims to experimentally investigate the spray cooling characteristics for active two-phase cooling of automotive power electronics. Tests are conducted on a small-scale, closed loop spray cooling system featuring a pressure atomized spray nozzle. Two types of refrigerants, HFC-134a (R-134a) and HFO-1234yf, are selected as the working fluids. The test section (heater), made out of oxygen-free copper, has a 1-cm2 plain, smooth surface prepared following a consistent procedure, and would serve as a baseline case. Matching size thick film resistors, attached onto the copper heaters, generate heat and simulate high heat flux power electronics devices. The tests are conducted by controlling the heat flux in increasing steps, and recording the corresponding steady-state temperatures to obtain cooling curves. The working fluid is kept at room temperature level (22oC). Performance comparisons are made based on heat transfer coefficient (HTC) and critical heat flux (CHF) values. Effects of spray characteristics and liquid flow rates on the cooling performance are investigated with the selected coolants. Three types of commercially available nozzles that generate full-cone sprays with fine droplets are utilized in the tests. Effect of liquid flow rate is evaluated varying flow rates at 2, 3, 4 ml/s. The experimental results obtained from this study provide a framework for spray cooling performance with the current and next-generation refrigerants aimed for advanced thermal management of automotive power electronics.

As a result of the intense air-water interaction in the spray nozzle, air-mist spray is one of the most promising technologies for attaining high heat transfer. CFD simulations and multivariable linear regression were used in the first part of this study to analyze the air-mist spray produced by a flat-fan atomizer and to predict the heat transfer coefficient using the casting operating conditions such as air pressure, water flow rate, cast speed and standoff distance. For the air-mist spray cooling simulation, a four-step simulation method was utilized to capture the turbulent flow and mixing of the two fluids in the nozzle, as well as the generation, transport, and heat transfer of droplets. Analysis of the casting parameters showed that an increase in air pressure results in efficient atomization, increases the kinetic energy of the droplets and produces smaller droplet size thus, the cooling of the slab increases significantly. Also, a decrease in water flow rate, standoff distance and casting speed would result in more efficient cooling of the steel slab. The second part of the study investigated the solidification of steel in the secondary cooling region. Caster geometry and casting parameters were studied to evaluate their impact on the solidification of steel. The parameters studied include roll gap, roll diameter, casting speed and superheat. It was found that a smaller ratio of roll gap to roll diameter is more efficient for adequate solidification of steel without any defect. Casting speed was found to have a significant effect on the solidification of steel while superheat was found to be insignificant in the secondary zone solidification. The result from the air-mist spray cooling was integrated into the solidification model to investigate the solidification of steel in the entire caster and predict the surface temperature, shell growth and metallurgical length. To replicate real casting process, temperature dependent material properties of the steel were evaluated using a thermodynamic software, JMatPro. The air-mist spray model was majorly investigated using ANSYS Fluent 2020R1 CFD tool while the solidification of steel was studied using STARCCM+ CFD software. Using the findings from this study, continuous casting processes and optimization can be improved.

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During this investigation, vibration induced droplet generation from a liquid layer was examined as a means for achieving high heat flux evaporative cooling. Experiments were performed in which droplets were generated from a liquid layer using a submerged vibrating piezoelectric driver. Parameters determined during this investigation of droplet generation were droplet mass flow rate, droplet size, driver frequency, driver voltage, and liquid layer thickness. The results showed that as the liquid layer thickness was increased, the frequencies and frequency ranges at which droplet generation occurred decreased. Droplet mass flow rates were varied by adjustment of the liquid layer thickness, driver frequency, and driver voltage. The dependence of the drivers displacement, velocity, and acceleration on frequency and voltage was determined, and the drivers frequency response was related to the occurrence of droplet generation. As a result, a frequency-dependent dimensionless parameter was proposed as a method for predicting droplet generation from the surface of the liquid layer. The dimensionless parameter is a combination of the Froude number and the dimensionless driver acceleration. The measurements have shown that droplet generation occurs when the parameter is between distinct upper and lower bounds. An analytical heat transfer model of a droplet cooling heat transfer cell was developed to simulate the performance of such a cell for thermal management applications. Using droplet flow rates determined as functions of driver voltage, driver frequency, liquid layer thickness, and interception distance, the heat transfer rate of a droplet cooling heat transfer cell was predicted for varied heat source temperatures and cell conditions. The heat transfer model was formulated in such a way as to accommodate a number of parameter variations that can be used for the design of a simple heat transfer cell. The model was used to determine the effect of droplet cooling on the heat transfer rate from a heated surface, but it can also be used to determine the influence of any of the other embodied parameters that may be of interest for thermal management applications.