Simple model for predicting microchannel heat sink performance and optimization

A simple model was established to predict microchannel heat sink performance based on energy balance. Both hydrodynamically and thermally developed effects were included. Comparisons with the experimental data show that this model provides satisfactory thermal resistance prediction. The model is further extended to carry out geometric optimization on the microchannel heat sink. The results from the simple model are in good agreement as compared with those obtained from three-dimensional simulations.     

Periodic flow boiling in a non-uniformly heated microchannel heat sink

Hydrodynamic and thermal characteristics of flow boiling in a non-uniformly heated microchannel were studied. Experiments were performed with a single microchannel and a series of microheaters to study the microscale boiling of water under axially non-uniform heat input conditions. A simultaneous real time visualization of the flow pattern was performed with the measurement of experimental parameters. Tests were performed over a mass flux of 309.8 kg/m² s, and heat flux of 200–600 kW/m². Test results showed different fluctuations of heated wall temperature, pressure drop, and mass flux with variations of the heat input along the flow direction. The unique periodic flow boiling in a single microchannel was observed at all heat flux conditions except for the increasing heat input distribution case which is the nearly uniform effective heat input distribution condition. The instability is correlated with flow pattern transition. For the nearly uniform effective heating condition, no fluctuation of the wall temperature, pressure drop, or mass flux was observed. We can relieve the instability by increasing total heat input along the flow direction and predict the instability using the transition criteria and flow pattern map.     

Lattice Boltzmann simulation of heat transfer and fluid flow in a microchannel with nanofluids

Mathematical modeling is performed to simulate forced convection flow of 47 nm- Al₂O₃/water nanofluids in a microchannel using the lattice Boltzmann method (LBM). Single channel flow and conjugate heat transfer problem are taken into consideration and the heat transfer rate using a nanofluid is examined. Simulations are conducted at low Reynolds numbers (2 ≤ Re ≤ 16). The computed average Nusselt number, which is associated with the thermal conductivity of nanofluid, is in the range of 0.6 ￡ [`(Nu)] ￡ 13 0.6 \le \overline{Nu} \le 13 . Results indicate that the average Nusselt number increases with the increase of Reynolds number and particle volume concentration. The fluid temperature distribution is more uniform with the use of nanofluid than that of pure water. Furthermore, great deviations of computed Nusselt numbers using different models associated with the physical properties of a nanofluid are revealed. The results of LBM agree well with the classical CFD method for predictions of flow and heat transfer in a single channel and a microchannel heat sink concerning the conjugate heat transfer problem, and consequently LBM is robust and promising for practical applications.     

Thermal transport and performance analysis of pressure- and electroosmotically-driven liquid flow microchannel heat sink with wavy wall

The present study investigates the microchannel heat sinks (MCHSs) with smooth and wavy wall for pure electroosmotic flow (EOF), pressure-driven flow (PDF) and combined electroosmotic and pressure-driven flow (PDF + EOF). A three-dimensional numerical analysis was performed for EOF, PDF and combined flow (PDF + EOF) through finite volume analysis. The EOF was combined with the PDF to enhance the flow rate and to reduce the thermal resistance of the MCHS. The effect of wall waviness on electroosmosis and thermal performance of the MCHS was critically investigated for flow rate, friction factor, Nusselt number, thermal resistance and pumping power. The design variables related to the wavelength and amplitude and width of microchannel were investigated for their effect on the overall thermal performance and pumping power. The electroosmosis not only increases the flow rate but also suppresses the secondary flow developed due to the topology of the microchannel walls. The non-uniformity of the velocity and temperature is reduced due to the application of the EOF in a PDF and combined flow (PDF + EOF).     

Experimental investigation of flow boiling characteristics in a cross-linked microchannel heat sink

This paper experimentally investigates flow boiling characteristics in a cross-linked microchannel heat sink at low mass fluxes and high heat fluxes. The heat sink consists of 45 straight microchannels each with a hydraulic diameter of 248 μm and heated length of 16 mm. Three cross-links, of width 500 μm, are introduced in the present microchannel heat sink to achieve better temperature uniformity and to avoid flow mal-distribution. Flow visualization, flow instability, two-phase pressure drop, and two-phase heat transfer measurements are conducted using the dielectric coolant FC-72 over a range of heat flux from 7.2 to 104.2 kW/m², mass flux from 99 to 290 kg/m² s, and exit quality from 0.01 to 0.71. Thermochromic liquid crystals are used in the present study as full-field surface temperature sensors to map the temperature distribution on the heat sink surface. Flow visualization studies indicate that the observed flow regime is primarily slug. Visual observations of flow patterns in the cross-links demonstrate that bubbles nucleate and grow rapidly on the surface of the cross-links and in the tangential direction at the microchannels’ entrance due to the effect of circulations generated in those regions. The two-phase pressure drop strongly increases with the exit quality, at x_e,o < 0.3, and the two-phase frictional pressure drop increases by a factor of 1.6–2 compared to the straight microchannel heat sink. The flow boiling heat transfer coefficient increases with increasing exit quality at a constant mass flux, which is caused by the dominance of the nucleation boiling mechanism in the cross-link region.     

Convective boiling in a parallel microchannel heat sink with a diverging cross section and artificial nucleation sites

To develop a highly stable microchannel heat sink for boiling heat transfer, three types of diverging microchannels (Type 1, Type 2 and Type 3) were designed to experimentally investigate the effect of different distributions of artificial nucleation sites (ANS) on the enhancement of flow boiling heat transfer, in 10 parallel diverging microchannels with a mean hydraulic diameter of 120 μm. Water was used as the working fluid with mass flux, based on the mean cross section area, ranging from 99 to 297 kg/m² s. The Type-1 system did not contain any ANS; the Type-2 system contained ANS distributed uniformly along the downstream half of the channel; and the Type-3 system contained ANS distributed uniformly along the entire channel. The ANS are laser-etched pits on the bottom wall of the channel and have a mouth diameter of approximately 20-22 μm, as indicted by the heterogeneous nucleation theory. The results of the present study reveal that the presence of ANS for flow boiling in parallel diverging microchannels significantly reduces the wall superheat and enhances the boiling heat transfer performance. The Type-3 system shows the best boiling heat transfer performance.     

Thermal performance of a carbon fiber composite material heat sink in an FC-72 thermosyphon

This study analyzes the use of a carbon fiber epoxy heat sink for evaporator surface enhancement in a FC-72 thermosyphon. The pin-fin heat sink features 945 small-cross-section (1.27 mm by 0.965 mm) fins fabricated with an integral base plate. These fins have a high thermal conductivity (500 W/m K) along the length of the fin. The influence of heat load, thermosyphon fill volume, and condenser operating temperature on the overall thermal performance is examined. The results of this experiment provide significant insight into the possible implementation and potential benefits of carbon-fiber heat sink technology in two-phase flow leading to significant improvements in thermal management strategies for advanced electronics.     

Optimization of an ammonia-cooled rectangular microchannel heat sink using multi-objective non-dominated sorting genetic algorithm (NSGA2)

The ever decreasing size of modern electronic packaging has induced researchers to search for an effective and efficient heat removal system to handle the continuously increasing power density. Investigations have involved different geometry, material and coolant to address the thermal management issues. This paper reports the potential improvement in the overall performance of a rectangular microchannel heat sink using a new gaseous coolant namely ammonia gas. Using a multi-objective general optimization scheme with the thermal resistance model as an analysis method in combination with a non-dominated sorting genetic algorithm as an optimization technique, it was found that significant reduction in the total thermal resistance up to 34?% for ammonia-cooled compared to air-cooled microchannel heat sink under the same operating conditions is achievable. In addition, a considerable decrease in the microchannel heat sink’s mass up to 30?% was achieved due to the different heat sink’s material used.     

Investigation of heat transfer of nanofluids in turbulent flow in a cylindrical channel

Turbulent flow of nanofluids based on the distilled water with aluminum and silicon oxide particles of different sizes in a cylindrical channel is studied. The results of the measurements of the heat transfer coefficient and the pressure difference are presented. The maximum volume concentration of the particles was not greater than two percents. The dependence of the heat transfer coefficient on the nanoparticle concentration and their sizes and material is studied. It is shown that a considerable increase in the nanofluid heat transfer coefficient, compared with the corresponding value for water, may generally be expected. At the same time, the heat transfer coefficient of a nanofluid depends on the nanoparticle size and material; because of this, under certain conditions the nanofluid heat transfer coefficient can turn out to be lower than that of the baseline fluid. Situations, when this can occur, are established. It is for the first time experimentally shown that the nanofluid viscosity coefficient depends not only on the nanoparticle size but also on its material.     

Topology optimization and heat dissipation performance analysis of a micro-channel heat sink

Junction temperature in the electronic packaging process is one of the critical factors affecting the service life of electronic devices. A micro-channel heat sink is a common heat dissipating device used to reduce the thermal resistance between components and substrate. In order to maximize the heat dissipation while minimizing the pressure drop, this paper adopts a topology optimization method. A material interpolation method based on variable density principle is used together with a moving asymptote algorithm for the optimization. The physics is governed by the heat and mass transfer, coupled with the momentum conservation in the fluid. Four parameters are varied in order to investigate their influence on the optimization process. A three-dimensional geometry has been constructed to study the flow field and the results are compared to a reference case to verify the temperature uniformity and thermal performance of the model. It is demonstrated that the optimized design of the micro-channel heat sink is reliable and effective.     

Two-phase pressure drop and flow visualization of FC-72 in a silicon microchannel heat sink

The rapid development of two-phase microfluidic devices has triggered the demand for a detailed understanding of the flow characteristics inside microchannel heat sinks to advance the cooling process of micro-electronics. The present study focuses on the experimental investigation of pressure drop characteristics and flow visualization of a two-phase flow in a silicon microchannel heat sink. The microchannel heat sink consists of a rectangular silicon chip in which 45 rectangular microchannels were chemically etched with a depth of 276 μm, width of 225 μm, and a length of 16 mm. Experiments are carried out for mass fluxes ranging from 341 to 531 kg/m² s and heat fluxes from 60.4 to 130.6 kW/m² using FC-72 as the working fluid. Bubble growth and flow regimes are observed using high speed visualization. Three major flow regimes are identified: bubbly, slug, and annular. The frictional two-phase pressure drop increases with exit quality for a constant mass flux. An assessment of various pressure drop correlations reported in the literature is conducted for validation. A new general correlation is developed to predict the two-phase pressure drop in microchannel heat sinks for five different refrigerants. The experimental pressure drops for laminar-liquid laminar-vapor and laminar-liquid turbulent-vapor flow conditions are predicted by the new correlation with mean absolute errors of 10.4% and 14.5%, respectively.     

Pool boiling heat transfer performance of Newtonian nanofluids

Experimental measurements were carried out on the boiling heat transfer characteristics of γ-Al₂O₃/water and SnO₂/water Newtonian nanofluids. Nanofluids are liquid suspensions containing nanoparticles with sizes smaller than 100 nm. In this research, suspensions with different concentrations of γ-Al₂O₃ and SnO₂ nanoparticles in water were studied under nucleate pool boiling heat transfer conditions. Results show that nanofluids possess noticeably higher boiling heat transfer coefficients than the base fluid. The boiling heat transfer coefficients depend on the type and concentration of nanoparticles.     

Measurements and high-speed visualizations of flow boiling of a dielectric fluid in a silicon microchannel heat sink

Experiments were conducted to investigate flow boiling heat transfer to a dielectric fluid in a silicon chip-integrated microchannel heat sink. Twenty-four microchannels, each 389 μm × 389 μm in cross-section, were fabricated into the 12.7 mm × 12.7 mm silicon substrate. High-speed visualizations (at 12,500 frames per second) were performed simultaneously with heat transfer and pressure drop measurements to investigate the physics of flow boiling in parallel microchannel arrays. At low heat fluxes, bubbly flow is dominant, with the bubbles coalescing to form vapor slugs as the heat flux is increased. At high heat fluxes, the flow regimes in the downstream portion of the microchannels are characteristic of alternating wispy-annular flow and churn flow, while flow reversal is observed in the upstream region near the microchannel inlet. Local heat transfer measurements, obtained at three flow rates ranging from 35 to 60 ml/min, show that at lower heat fluxes, the heat transfer coefficient increases with increasing heat flux. The heat transfer coefficient in fully developed boiling is seen to be independent of flow rate in this range. At higher heat fluxes (exceeding 542, 673, 730 kW/m², respectively, for flow rates of 35, 47 and 60 ml/min), this trend is reversed, and the heat transfer coefficient decreases with further increases in heat flux due to partial dryout in some of the microchannels. Heat fluxes at which fully developed boiling is achieved depend on the flow rate. The pressure drop in fully developed boiling increases with increasing heat flux and is independent of flow rate for the test conditions considered in this work.     

The variation of heat transfer in a two‐sided lid‐driven differentially heated square cavity with nanofluids containing carbon nanotubes for physical properties of fluid dependent on temperature

The behavior of nanofluids containing cylindrical nanoparticles are investigated numerically inside a two‐sided lid‐driven differentially heated square cavity to gain insight into the convective recirculation and flow processes induced by a nanofluid. The physical properties of the base fluid such as viscosity, thermal conductivity and thermal expansion coefficient are, respectively, assumed to be temperature independent (taking the mean temperature of the left and right walls) and temperature dependent. A model is developed to analyze the behavior of nanofluids taking into account the nanoparticle volume fraction whereas the transport equations are solved numerically with finite volume approach using SIMPLEC algorithm. The left and right moving walls are maintained at different constant temperatures while the upper and bottom walls are thermally insulated. The directions of the moving walls were considered in a way that the force and natural convections aid each other. The governing parameter Richardson number was 0.1<Ri<50.0 but due to space constraints only the results for 0.1<Ri<10.0 from fluid flow are presented. It was found that the temperature dependency of physical properties at different Richardson numbers and nanoparticle volume fractions affects the fluid flow and heat transfer in the cavities. Finally, comparisons between the behaviors of the average Nusselt number at the left wall for two cases are presented. Copyright © 2011 John Wiley & Sons, Ltd.     

Effect of nanofluids on the performance of a miniature plate heat exchanger with modulated surface

In the present work, the effect of the use of a nanofluid in a miniature plate heat exchanger (PHE) with modulated surface has been studied both experimentally and numerically. First, the thermophysical properties (i.e., thermal conductivity, heat capacity, viscosity, density and surface tension) of a typical nanofluid (CuO in water, 4% v/v) were systematically measured. The effect of surface modulation on heat transfer augmentation and friction losses was then investigated by simulating the existing miniature PHE as well as a notional similar PHE with flat plate using a CFD code. Finally, the effect of the nanofluid on the PHE performance was studied and compared to that of a conventional cooling fluid (i.e., water). The results suggest that, for a given heat duty, the nanofluid volumetric flow rate required is lower than that of water causing lower pressure drop. As a result, smaller equipment and less pumping power are required. In conclusion, the use of the nanofluids seems to be a promising solution towards designing efficient heat exchanging systems, especially when the total volume of the equipment is the main issue. The only drawbacks so far are the high price and the possible instability of the nanoparticle suspensions.     

Heat transfer and pressure drop in fractal microchannel heat sink for cooling of electronic chips

In this paper, the improved design of fractal branching channel net that can meet the demand for cooling of rectangular electronic chip with arbitrary ratio of length to width is presented. A theory model is proposed that can be used to estimate the performance of heat transfer and pressure drop approximately. It is found that the optimal total branching level is 7 and the ratio of length to width is 1.87 at the fixed cooling surface for fractal microchannel heat sink.     

单层微通道热沉拓扑结构对芯片中心热点的降温效能研究

通过热流固耦合模拟分析得到了不同微通道结构热沉基底的温度场及微通道内速度场,研究了相同入流功率下不同单层微通道拓扑结构对中心有高热流密度热点芯片的散热能力。结果表明:相同入流功率(0.05W)下,不同结构的散热能力排序由高到低为Y分形、弯曲散射、直散射(双侧出流)、直螺旋、直散射(单侧出流)、圆螺旋、树状分形、直槽结构;采用中心入流可有效降低芯片中心热点附近的温度,对于中心入流的散射结构,采用对称出流结构可提升其流动传热性能;Y分形结构具有良好的流动传热特性,对于热源面和中心热点均具有良好的散热效果。     

Thermal performance analysis of nanofluids in a thermosyphon heat pipe using CFD modeling

A computational fluid dynamics model for simulation of a thermosyphon with two-phase flow including phase change heat transfer was developed. De-ionized water and CuO/Water nanofluid were used as working fluids in the thermosyphon. Results show that, maximum heat flux of the nanofluid is about 46 % higher than that of water. Also by increasing the nanofluid concentration, the wall temperature decreases, and the concentration of 1 wt% is the optimum concentration.