Development of additive manufactured cooling components with micro- and minichannels

Important results from the project

We made significant progress according to our plan, conducting LES of AM rough surface turbulent flows, both with and without heat transfer. Our database and post-processing tools are fully available to validate both existing and future rough wall models. Progress continued as planned by completing LES of AM surface turbulent flows with and without heat transfer, using the actual cooler geometry. The combined approach of experiments and CFD helped Setrab optimize their cooling channel geometry.

Expected long term effects

By adopting a multidisciplinary approach and integrating CFD simulations with AM technology, we generated new insights into fluid flow and heat transfer in AM-produced micro- and minichannels cooling components, which were disseminated across various industrial sectors. AM-produced coolers with micro-channel configurations enhance overall heat transfer coefficients by approximately 50% to 100% compared to conventional coolers. This also resulted in a significant increase in pressure loss.

Approach and implementation

Both numerical and experimental studies were conducted on AM-produced coolers with microchannel manifolds. An exhaustive open-source model was developed to obtain the required rough geometry and its characterization essential for simulations. A modified solver was implemented to account for the adjusted energy equation due to cyclic boundary conditions. Local distributions of temperature and velocity, as well as global heat transfer coefficients and pressure drop, were obtained.