Experimental Characterization of a Microchannel Heat Sink Made by Additive Manufacturing

Collins, Ivel L.; Weibel, Justin A.; Pan, Liang; Garimella, Suresh V.

doi:10.1109/itherm.2018.8419588

Cited by 12 publications

(7 citation statements)

References 19 publications

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“…Although rectangular and permeable wall microchannels with D h 500 µm have been successfully 3D printed using the DMLS method [34], triangular microchannels had yet to be investigated. The design of triangular structures requires special attention as the selection of apex angles between two adjacent surfaces (α > 45 • ) is critical to prevent any overhanging structures with support material underneath [35].…”

Section: Microchannel Geometrical and Surface Roughness Evaluationmentioning

confidence: 99%

Thermal and hydraulic performance of Al alloy-based 3D printed triangular microchannel heatsink governed by rough walls with graphene and alumina nanofluids as working liquid

Nadarajah,

Mohamed,

Abdullah

et al. 2024

J. Micromech. Microeng.

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Microchannel heat sinks (MCHS) are known for providing enhanced cooling performance but their fabrication requires complex and multi step processes. The recent development of additive manufacturing has enabled the fabrication of state-of-art monolithic structures that had been impossible to build using conventional methods. In this work, a monolithic cross-flow triangular cross-section microchannel heat sink was fabricated from aluminum alloy (AlSi10Mg) using the Direct Metal Laser Sintering (DMLS) process. The microchannel wall surface roughness was measured and the cross-section shrinkage of the microchannels was compared with the initial design hydraulic diameter of 500 µm - 1 000 µm., The MCHS with an initial design hydraulic diameter of 750 µm possessed a relative wall surface roughness, Ra of 7.7%. The triangular cross-section hydraulic diameter underwent a shrinkage of 15.2% and 5.3% in terms of the reduction in angle between adjacent side alloys. Experiments were conducted for Reynolds numbers between 50 and 275 with nanofluids containing graphene and Al2O3 nanoparticles in water/water +10% ethylene glycol; these were compared with their respective base fluids. For this range of Reynolds numbers, with water as coolant, the rough wall surface elevated the friction factor to least double that of smooth microchannels. The Poiseuille number indicated that flow was laminar developed with base fluid and laminar developing with nanofluid as coolant. Despite providing the lowest thermal resistance, the graphene nanoparticles in water created the greatest pressure drop leading to a reduced performance coefficient. Al2O3 nanoparticles in water/water +10% Ethylene glycol were found to have 7.7% and 20% better performance coefficients than their respective base fluids.

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Section: Microchannel Geometrical and Surface Roughness Evaluationmentioning

confidence: 99%

Thermal and hydraulic performance of Al alloy-based 3D printed triangular microchannel heatsink governed by rough walls with graphene and alumina nanofluids as working liquid

Nadarajah,

Mohamed,

Abdullah

et al. 2024

J. Micromech. Microeng.

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“…Jain [30] discussed the unique capabilities of A.M. in the field of thermal management, which are (1) High precision liquid-cooled microchannels can be realized by the features with as small as 20 µm dimension and ±2 µm tolerances; (2) Increased surface area to enhance convection; (3) Integrated composite structure with optimized material pallet. A.M. used to fabricate the microchannel heat exchangers is not a challenge [31,32], the real challenge is how to design a microchannel heat exchanger which can achieve good performance by virtue of the advantages of A.M., especially in the application of the two-phase boiling.…”

Section: Microchannel Heat Sink Designmentioning

confidence: 99%

Study of Two-Phase Microchannel Heat Sink Fabricated by A.M. Technology for Energy Reuse in the Electronic Device

Chen

Zhao

2022

GEET

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Data centers’ electricity energy consumption accounts for 1% of global electricity demand and 0.3% of all global CO2 emissions. Energy reuse as a core of a net zero carbon data center, as a macro goal benefiting to mankind, needs micro innovations from thermal engineers to reclaim the distributed and low-grade thermal energy from diversified electronic equipment. This article presents the attempt to combine the advantages of high-density heat transferring technology by two-phase microchannels and the agility of Additive Manufacturing (A.M.) technology into a heat sink by which thermal energy can be collected in premium quantity and quality. The heat sink prototype adopted the two-layer microchannel design by leveraging the unique capability of A.M. technology to form complicated spatial geometric features, such as the functional channel profiles with diverged cross-sections along the flow direction, intermittent channels, and curved channels. It was fabricated at one-time processing by AlSi10Mg powder SLS/SLM, had an exterior base area of 25 cm2, and interior micro-fins with a minimal thickness of 0.2 mm and fin pitch of 0.38 mm. A test rig had been built to validate the thermal dynamic and hydraulic performance of this microchannel heat exchanger working with HFE 7100 as the coolant. The heat flux under certain wall superheat and pressure drop catches the equivalent grade of microchannels made by conventional micro-cutting approaches on copper or aluminum. The maximum inlet coolant temperature could be elevated up to 60.0 °C with less than 90.0 °C CPU case temperature, which provides the feasibility of high-grade heat recovery. The test results present the promising prospects of this design and A.M. technology in the field of two-phase microchannel heat exchanging, by which the electronic devices in megawatt hyperscale data center can be changed from energy consumers to energy generators for the greenhouse, district heating, and hot water system.

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“…In general, there are two approaches which need to be focused on. One approach is the optimization of the geometry [6][7][8][9][10][11] and the other approach is the development of polymer composite material with thermal conductive fillers. [12][13][14][15][16][17][18][19] Arie et al 6 focused on the design of a polymer heat exchanger by directly connecting the hot and the cold side from the heat exchanger by using additive manufacturing.…”

Section: Introductionmentioning

confidence: 99%

“…In their study, Tiwari et al 8 focused on the development of an additively manufactured distributor for single‐phase flows in an heat exchanger. Collins et al 9 fabricated a permeable membrane microchannel heat sink geometry using direct metal laser sintering of an aluminum alloy. For active cooling of small flat surfaces, Barba et al 10 developed a polymer microchannel heat sink consisting of a circular channel embedded in a rectangular polymer block through which a gas flows.…”

Section: Introductionmentioning

confidence: 99%

Influence of printing direction and filler orientation on the thermal conductivity of 3D printed heat sinks

Moser,

Strasser,

Tanda

et al. 2023

SPE Polymers

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Prototype development nowadays can rarely be imagined without 3D printing. In the fast‐moving electronics industry, 3D printing is a good way to react quickly to changing developments, for example, when it comes to heat sinks made of thermally conductive material. 3D printing of thermally conducting plastics, which are also electrically insulating, is an ideal candidate for the rapid generation of heat sink. Nevertheless, 3D printing also shows some drawbacks in regard to properties of the printed parts, as porosities or layer adhesion, emerging from layer deposition in the process. Therefore, the aim of this work was to investigate the influence of the orientation of fillers on the thermal conductivity of filled polylactic acid (PLA). PLA was filled with amounts of 15–45 wt.% of boron nitride and aluminum granules and printed into heat sinks in two different orientations to investigate this influence on the thermal conductivity. The printed heat sinks were then placed on a heated aluminum block and the thermal transport was examined with an infrared camera. It could be shown that especially with platelet‐shaped fillers such as boron nitride, the orientation of these in the test specimen has a large influence on the thermal conductivity.Highlights 3D printing of thermally conductive heat sinks Thermal characterization of 3D printed heat sinks Computer tomography scans of heat sinks to evaluate the porosity

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Experimental Characterization of a Microchannel Heat Sink Made by Additive Manufacturing

Cited by 12 publications

References 19 publications

Thermal and hydraulic performance of Al alloy-based 3D printed triangular microchannel heatsink governed by rough walls with graphene and alumina nanofluids as working liquid

Thermal and hydraulic performance of Al alloy-based 3D printed triangular microchannel heatsink governed by rough walls with graphene and alumina nanofluids as working liquid

Study of Two-Phase Microchannel Heat Sink Fabricated by A.M. Technology for Energy Reuse in the Electronic Device

Influence of printing direction and filler orientation on the thermal conductivity of 3D printed heat sinks

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