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Design, Fabrication, and Testing of Cross Flow Micro Heat Exchangers. Chad Randall Harris Louisiana State University and Agricultural & Mechanical College

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Design, Fabrication, and Testing of Cross Flow Micro Heat Exchangers. Chad Randall Harris Louisiana State University and Agricultural & Mechanical College Louisiana State University LSU Digital Commons LSU Historical Dissertations and Theses Graduate School 2001 Design, Fabrication, and Testing of Cross Flow Micro Heat Exchangers. Chad Randall Harris Louisiana State University and Agricultural & Mechanical College Follow this and additional works at: https://digitalcommons.lsu.edu/gradschool_disstheses Recommended Citation Harris, Chad Randall, "Design, Fabrication, and Testing of Cross Flow Micro Heat Exchangers." (2001). LSU Historical Dissertations and Theses. 290. https://digitalcommons.lsu.edu/gradschool_disstheses/290 This Dissertation is brought to you for free and open access by the Graduate School at LSU Digital Commons. It has been accepted for inclusion in LSU Historical Dissertations and Theses by an authorized administrator of LSU Digital Commons. For more information, please contact [email protected]. INFORMATION TO USERS This manuscript has been reproduced from the microfilm master. UMI films the text directly from the original or copy submitted. Thus, some thesis and dissertation copies are in typewriter face, while others may be from any type of computer printer. The quality of this reproduction is dependent upon the quality of the copy submitted. Broken or indistinct print, colored or poor quality illustrations and photographs, print bleedthrough, substandard margins, and improper alignment can adversely affect reproduction. In the unlikely event that the author did not send UMI a complete manuscript and there are missing pages, these will be noted. Also, if unauthorized copyright material had to be removed, a note will indicate the deletion. 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Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. DESIGN, FABRICATION, AND TESTING OF CROSS FLOW MICRO HEAT EXCHANGERS A Dissertation Submitted to the Graduate Faculty of the Louisiana State University and Agricultural and Mechanical College in partial fulfillm e nt o f the requirements for the degree o f Doctor o f Philosophy in The Department of Mechanical Engineering by Chad Harris B.S., Louisiana State University, 1997 May 2001 Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. UMI Number 3016553 umt UMI Microform 3016553 Copyright 2001 by Bell & Howell Information and Learning Company. All rights reserved. This microform edition is protected against unauthorized copying under Title 17, United States Code. Bell & Howell Information and Learning Company 300 North Zeeb Road P.O. Box 1346 Ann Arbor. Ml 48106-1346 Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. DEDICATION To my family and my wife, Katy ii Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. ACKNOWLEDGMENTS I would like to give thanks to the people that I have worked w ith since I began my graduate career. M y advisor, Dr. Kevin K elly has always offered advice and been fair. His cooperation has enabled me to finish my work efficiently. There were several other people essential to the proficient completion o f the micro heat exchangers. Dr. Mircea Despa has assisted in many facets o f the project and is the person who made molding possible. Andrew McCandless was always there to answer any micro fabrication procedure questions. Paul Rodriguez provided advice on a variety o f issues. Emil Geiger was essential to the high quality o f the final microstructures produced. I am grateful to Dr. Elizabeth Podlaha, Dr. Dimitris Nikitopoulus, and Dr. Warren Waggenspack for accepting my invitation to be members o f my committee. This work was made possible by innovative equipment available at the Center for Advanced Microstructures and Devices as well as funding provided by the Defense Advanced Research Project Agency. iii Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. TABLE OF CONTENTS Dedication .................................................................................................. ii Acknowledgments .................................................................................... iii Abstract ..................................................................................................... vi Chapter I-Introduction ............................................................................. 1 Chapter II-Scaling ..................................................................................... 3 n .l. Analysis......................................................................................... 3 H.2. Discussion ...................................................................................... 4 Chapter Di-Literature Review .................................................................6 ffl.1 . Conventional Scale Cross Row Heat Exchangers ..........................8 IH.2. Compact Heat Exchangers ............................................................ 9 ffl.3. Electronic Cooling ....................................................................... 10 m.4. Cross Row M icro Heat Exchangers with Equal Channel Dimensions .................................................................................. 11 m.5. Heat Exchanger Comparison ........................................................ 13 m.6. Other Micro Heat Exchangers ...................................................... 14 Chapter IV-Design and Modeling ...........................................................15 IV. 1. Conceptual Design ...................................................................... 15 IV.2. Performance Parameters ...............................................................17 IV.3. Design Constraints ...................................................................... 18 IV.4. Optimization and Modeling Calculations .................................... 20 IV.5. Results ........................................................................................ 31 Chapter V-Fabrication ........................................................................... 38 V .l. Overview o f LIG A Process .......................................................... 38 V.2. Procedure ..................................................................................... 39 V.3. Results ......................................................................................... 56 Chapter VI-Testing ................................................................................. 59 VI. 1. Apparatus................................................................................... 59 VI.2. Procedure .................................................................................... 60 VL3. Uncertainty Analysis ................................................................... 65 V IA Results ........................................................................................ 65 Chapter VII-Metal Cross Flow Micro Heat Exchanger ....................... 73 V n.l. Introduction ............................................................................... 73 iv Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. VII.2. Design ....................................................................................... 73 VH.3. Fabrication .................................................................................87 V IIA Testing ......................................................................................100 Chapter Vm-Performance Discussion ................................................. 106 Chapter IX-ConcIusions and Recommendations ................................ 110 IX. 1 Conclusions ............................................................................... 110 IX.2 Recommendations for Future Work ............................................ I l l Bibliography.......................................................................................... 112 Nomenclature ......................................................................................... 118 Appendix A: Program for Design Optimization ................................. 119 Appendix B: Finite Element Modeling................................................. 126 Appendix C: Uncertainty Analysis.......................................................131 Appendix D: Microfabrication Procedures ......................................... 136 Vita ..........................................................................................................138 V Reproduced with permission of the copyright owner. Further reproduction
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