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

这项GOALI资助的目标是开发一种强大的、具有成本效益的、高产的粉末轧制/压印工艺，以生产多孔的传热/传质表面，该表面具有集成的微尺度特征、可控的孔隙率和使用铜粉和薄板材料的薄基材层。集成化、紧凑型和小型化设备的趋势导致高热负荷，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。近年来的研究主要集中在两相传热上，其中液相到汽相的相变（池沸腾）显著增加了热能传递水平。具有微尺度调制特征的多孔表面可使池沸改善180-300%。该基金将支持一项研究，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载荷条件下将颗粒材料形成具有可控孔隙率的微尺度特征所涉及的变形力学；(2)了解将同时产生的粉末和薄固体基材之间的结合。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，微反应堆，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中节省能源和空间。pi计划开发两个关于多孔表面应用和微尺度多孔特征制造的短期课程模块，并将其整合到现有的传热、设计和制造相关课程中。pi还计划在工业界、学术界和政府机构之间建立一个研讨会，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.