Additive manufacturing has made possible new geometry's design. The promise of these technologies is of prime importance in the heat exchanger's performances. Nevertheless, this fabrication process creates new more or less rough topologies, thus, different thermal-hydraulic behaviors, which are not fully known, controlled and predictable in the case of mini-channels (2 mm diameter in this study). The aim of this work is to test and compare the experimental thermal-hydraulic performances of different meandering mini-channels. They are obtained by a Laser-Powder Bed Fusion process with a circular or square cross-section. The geometry and the roughness of the channels are also characterized. Tests were conducted over a Reynolds number range of 200-6000. These experimental data are then used to build and validate a numerical model of the mock-up. The experimental and numerical results are consistent without requiring the use of tuning parameters. be compensated by the increase of the Nusselt number but to some limited extent. Indeed, several authors [4-8], [13], [18], show that the Nusselt number is not a linear function of the friction factor.The research about roughness modeling is not new but in the case of AM, the roughness features are very different from all other kind of roughness studied in past decades. Some authors [6], [16] mentioned these specific AM different roughness features, such as balling, hatch spacing, keyhole, dross… In the case of mini-channels, the flow is even more sensitive to these features and to high relative roughness. To study the AM roughness, there are mainly two numerical approaches.The first approach is roughness simulation, where "simulation" is to be heard in the sense that it consists in reproducing, i.e. meshing, the precise topology of the surfaces. It is not exclusively linked to AM but can be applied to it. Some authors create surfaces with: cones [19], cylinders [20], pavements [21], [22], half spheres [23] or ribs [24]. Some others created more complex structures as a mix of these previous elements [25] or a porous layer [26]. According to the present state of the art [27], the surface roughness consists on a fractal arrangement and mathematical functions are considered as the most accurate way to reproduce rough surfaces. The authors [28] use the Weierstraß-Mandelbrot function; the authors [29] combine a bi-cubic Coons patch; the authors [28], [30] use a parallel Lattice Boltzmann method; the authors [31] use the Johnson translator system [32][33][34]. This approach reproduces well the thermal-hydraulic performances of surfaces but needs an accurate surface characterization and a high simulation power. In fact, such surface meshing requires about 30 cells for each peak or between peaks. In other words, the flow around roughness peaks and through roughness valleys has to be captured by the grid. The technologies to characterize surfaces topologies are available at a laboratory scale but it requires open surfaces or else destructive measurements.
4The second approach is roug...