GOALI: Development of a Thermo-Mechanical Particulate Fabrication Technology for Mass Production of Integrated Microstructured Porous Surfaces w/ Controlled Porosity

该GOALI赠款的目的是开发一种强大的，具有成本效益和高生产率的粉末轧制/压花工艺，以使用铜粉和薄板材料生产具有集成微尺度特征，受控孔隙率和薄基底层的多孔热/质传递表面。 集成化、紧凑化和小型化设备的增加趋势导致高热负荷，并迫使跨学科研究努力开发紧凑、小型、高效和廉价的先进热交换器。最近的研究集中在两相传热，其中从液相到气相的相变（池沸腾）显着增加了热能传递的水平。 还发现具有微尺度调制特征的多孔表面可以提供高达180- 300%的池沸腾改善。 这笔赠款将支持一项研究，以开发一种新的制造工艺，以连续生产这种表面，并解决以下基本问题：（1）了解在复杂的机械和热负荷条件下将颗粒材料形成具有受控孔隙率的微尺度特征所涉及的变形力学，（2）了解粉末和薄固体基体之间将同时产生的结合。 当高度紧凑、集成和高效的先进热/质传递产品（热交换器、散热器、电子冷却装置、微反应器、燃料重整器）以可承受的成本提供给客户时，社会将实现这一创新的更广泛影响。 这将在热交换器的整个生命周期期间节省能量和空间。 研究院计划发展两个短期课程单元，分别介绍多孔表面的应用和微尺度多孔特征的制造，并将其纳入现有的传热、设计和制造相关课程。PI还计划在工业界、学术界和政府机构之间举办一个研讨会，讨论这项技术的潜在应用和改进。

The objective of this GOALI grant is to develop a robust, cost-effective and highly productive powder rolling/embossing process to produce porous heat/mass transfer surfaces with integrated micro-scale features, controlled porosity and thin substrate layer using copper powders and thin sheet material. The trend of increasing integrated, compact and miniaturized devices lead to high heat loads, and compel interdisciplinary research efforts to develop advanced heat exchangers that are compact, small, efficient and inexpensive. Recent studies focused on two phase heat transfer where phase transformation from liquid to vapor phase (pool-boiling) significantly increases the level of thermal energy transfer. It was also found that porous surfaces with micro-scale modulated features can provide pool-boiling improvements up to 180-300%. This grant will support a study to develop a novel manufacturing process to produce such surfaces continuously and address the following fundamental issues: (1) Understanding of the deformation mechanics involved in the forming of particulate materials into micro-scale features with controlled porosity under complex mechanical and thermal loading conditions, (2) Understanding of the bonding between powders and thin solid substrate that will be simultaneously generated. Broader Impacts of this innovation will be realized by the society when highly compact, integrated and efficient advanced heat/mass transfer products (heat exchangers, radiators, e-cooling units, micro-reactors, fuel reformers) are made available to customers at affordable cost. This would lead to energy and space savings during the entire life cycle of the heat exchangers. PIs plan to develop two short course modules on applications of porous surfaces and fabrication of micro-scale porous features, and integrate them into the existing heat transfer, design and manufacturing related courses. PIs also plan to develop a workshop among industry, academia and government agencies to discuss potential applications and improvements of this technology.