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Title:Design and performance characterization of novel heat exchanger geometries enabled by additive manufacturing
Author(s):Moon, Hyunkyu
Director of Research:King, William P
Doctoral Committee Chair(s):King, William P
Doctoral Committee Member(s):Jacobi, Anthony M; Miljkovic, Nenad; James, Kai
Department / Program:Mechanical Sci & Engineering
Discipline:Mechanical Engineering
Degree Granting Institution:University of Illinois at Urbana-Champaign
Subject(s):Heat exchanger
Heat transfer enhancement
Heat transfer augmentation
Genetic algorithm
Generative design
Shape optimization
Thermal energy storage
Abstract:Heat exchangers (HX) with optimal geometries are of particular interest because of their potential for high performance beyond current limits. This dissertation presents design, fabrication, and characterization of additively manufactured (AM) HX, and investigates HX geometries that are difficult or impossible to fabricate using conventional manufacturing methods. First, we designed, fabricated, and characterized an energy storage device based on an AM HX that stores heat from a flowing liquid coolant in the channel in the form of latent heat in a phase change material (PCM). We developed a design with internal fins extending from the channel wall to the flowing fluid and the external fins extending from the channel wall to the PCM, and then we fabricated and tested the device. The HX has 4X higher power density compared to the state-of-the-art (SOA) thermal energy storage devices. Second, we also report the design, fabrication, and characterization of single-phase internal flow AM HX under uniform heat flux condition using shape optimization. We developed a genetic algorithm to optimize the internal fin geometry for both laminar and turbulent flow regimes. The fin geometries were evaluated using two-dimensional (2D) finite element method (FEM) for laminar flow or Nusselt number-fin geometry correlation. The genetic algorithm proposed an optimal geometry that was fabricated and tested. The optimized device decreased the total thermal resistance by 4.5X for laminar flow and 3X for turbulent flow compared to a smooth device without internal fins. Finally, we report design, fabrication, and characterization of an ultra-power-dense tube-in-tube HX. We designed optimal inner fins that extend from channel wall to the inner flow region and outer fins that extend from channel wall to outer flow region by using a genetic algorithm. The optimized device was fabricated and tested and was also investigated using finite element simulations. We demonstrated a 23X increase in power density and 21X increased specific power when compared to conventional and commercially available compact HX technologies.
Issue Date:2021-03-23
Rights Information:Copyright 2021 Hyunkyu Moon
Date Available in IDEALS:2021-09-17
Date Deposited:2021-05

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