joining techniques for novel metal-polymer hybrid heat
TRANSCRIPT
Mechanical Science & Engineering
University of Illinois at Urbana-Champaign
Joining Techniques for Novel Metal-Polymer
Hybrid Heat Exchangers
Gowtham Kuntumalla, Yuquan Meng, Manjunath Rajagopal, Chenhui Shao, Placid Ferreira, Sanjiv Sinha
ASME IMECE - 10621 | Nov 12, 2019 University of Illinois 1
ASME IMECE 2019, Advanced Manufacturing Track: IMECE2019 - 10621
Low temperature heat recovery
ASME IMECE - 10621 | Nov 12, 2019University of Illinois 2
Polymers Metal
Metric
Cost
Corrosion & Fouling
Thermal Conductivity
Weight
Source: Cevallos, TherPESlab, Univ of Maryland
Source: Zhejiang TongxingRefrigeration Co., Ltd.
Current low temperature (< 150 °C) waste heat recovery HXNot viable & payback period > 3 years
BCS incorporated, 2018; Thekdi, Nimbalkar, Oak Ridge National Lab 2015
$ $$$
Minimal Problematic
Low (~ 0.2 W/m.K) High (~ 400 W/m.K)
Low High
~ 50% of industrial waste heat is < 200 °C
Introduction HX Design Characterization Mfg. Setup Summary
ASME IMECE - 10621 | Nov 12, 2019University of Illinois 3
Rajagopal et al., IJHMT 2019
Overall U across a certain cross-flow HX
For t = 2.5mm
Calculation specs:
𝑡𝑡𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 = 2.5mm,
Fouling resistance = 0.005 [m2K W−1],
Water flow rate (inner) = 0.005 kg/s,
Air flow rate (outer) ~ 4.7 m3/s
1MW waste heat source
Overall Heat Transfer Coefficient (U)
𝑼𝑼 =𝟏𝟏
𝟏𝟏𝒉𝒉𝒇𝒇𝒇𝒇𝒇𝒇𝒇𝒇 ∗ 𝑨𝑨𝒐𝒐
+ln 𝒓𝒓𝒊𝒊 + 𝒕𝒕𝒘𝒘𝒘𝒘𝒇𝒇𝒇𝒇
𝒓𝒓𝒊𝒊𝒌𝒌𝒘𝒘𝒘𝒘𝒇𝒇𝒇𝒇 ∗ 𝟐𝟐𝟐𝟐𝟐𝟐 + 𝟏𝟏
𝒉𝒉𝒘𝒘𝒘𝒘𝒕𝒕𝒇𝒇𝒓𝒓 ∗ 𝑨𝑨𝒊𝒊
Related Talk:Design of hybrid metal-polymer
heat exchanger for low temperature waste heat
recovery # 11421, Nov 11, 4:40 PM
Introduction HX Design Characterization Mfg. Setup Summary
Design of metal-polymer hybrid tubes
ASME IMECE - 10621 | Nov 12, 2019University of Illinois 4
*US patent application – in progress
Top wall cross section Wall unit cell Cut section of tubes(in 3D)
Cu-poly Joints
Material choicesMetal: Cu, AlPolymer: Kapton(Polyimides)
Cu-CuJoint
~ 50% savings in metal costs
Hybrid Tube(hollow)
Introduction HX Design Characterization Mfg. Setup Summary
Joints characterization at testing facility
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thermal paste
two thermocoupleshot air gun
Kapton
Universal Testing Machine
Introduction HX Design Characterization Mfg. Setup Summary
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Ultrasonic welding (Cu + Cu) - load curves
Ultrasonic weld joints b/w Copper and Copper
Peel Test Shear Test
Results @ 25°C only
(Peel test) (Shear test)
Introduction HX Design Characterization Mfg. Setup Summary
Illustrative Curves
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Ultrasonic welding (Cu + Cu) - test results
Results@ 25°C only
Peel Test Shear Test
Sample: ~ 10 mil (250 µm) Copper + ~ 10 mil Copper
Sonotrode vibration amplitudes
Sonotrode vibration amplitudes
10 repetitions per joint
(Peel test) (Shear test)
Ultrasonic weld joints b/w Copper and Copper
14 MPa
Introduction HX Design Characterization Mfg. Setup Summary
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Adhesive joints (Cu + poly) - load curves
Adhesive joints b/w Copper and Polymer
Peel Test
(ASTM D1876)
Shear Test
(ASTM D3165)
(Peel test) (Shear test)
Introduction HX Design Characterization Mfg. Setup Summary
Illustrative Curves
ASME IMECE - 10621 | Nov 12, 2019University of Illinois 9
Adhesive joints (Cu + poly) - test results
Shear Test (ASTM D3165)
Peel Test (ASTM D1876)
Sample: ~ 1mil (25µm) Copper + ~ 1mil Adhesive + ~ 1mil Kapton5 repetitions per joint
Adhesive joints b/w Copper and Polymer
(Peel test) (Shear test)
0.125MPa
Introduction HX Design Characterization Mfg. Setup Summary
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Takeaways: characterization of joints
Ultrasonic Welding (Cu + Cu):
• Kapton + Cu not possible
• Science not yet fully understood
• Empirical expts. to get best parameter set
Adhesives (Cu + poly):
• Weak link
• Tough to join Copper + Kapton
• Temperature Bond Strength
USW Shear Strength:~ 14 MPa(Only Cu + Cu)
Adhesive Shear Strength:~ 0.13 MPa (Cu + poly)
Introduction HX Design Characterization Mfg. Setup Summary
Copper/Copper Joints
Recent testing (after acceptance of this paper)
ASME IMECE - 10621 | Nov 12, 2019University of Illinois 11
Epoxy: good alternative joint for Cu/Poly.
Copper/Kapton Joints 5 repetitions per joint
* Not published in this paper
How does it work for Cu/Cu?
Epoxy Shear Strength:~ 0.35 MPa (Cu/poly)~ 0.55 MPa (Cu/Cu)
Target Operational Temperature = 150 °C
Introduction HX Design Characterization Mfg. Setup Summary
Manufacturing Setup - CAD
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Linear Actuator – Tape Dispensers
Rotation System – Collapsible Mandrel
*Adhesive dispensing, motor driver electronics not shown
Built in-house at UIUC
Introduction HX Design Characterization Mfg. Setup Summary
Manufacturing Setup – Actual setup
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Electronics
Samples made on this setup
Metal tape
Polymer tape
Introduction HX Design Characterization Mfg. Setup Summary
Working Video – Helical Tape Laying Process
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Introduction HX Design Characterization Mfg. Setup Summary
Summary
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Design
TestingJoints
Prototype
Epoxy joints are
promising
Acknowledgements
University of Illinois 16
PI: Prof. Sanjiv Sinha Prof. Nenad Miljkovic
Prof. Placid Ferreira
Prof. Srinivasa Salapaka
Prof. Chenhui Shao
DOE Award No. DE-EE0008312
Our team
ASME IMECE - 10621 | Nov 12, 2019
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Appendix
Enhancing polymers
18
Tavman, I.H., J. App. Poly. Sci. (1996)
Aluminumpowders in HDPE
0 10 20 30 40 50 60Vol (%)
Rela
tive
tens
ile st
reng
th
1
0.6
0.2
1.4 Air inclusions at interface reduce overall strength
-40 %
Objective:
- High transverse heat transfer (keff ~ 1 Wm-1K-1)- Have higher operating pressures (~ 150 psi)
Maximum operating pressurefor polymer pipes ~ 150 psi
Manju Rajagopal, Talk: # 11421, University of Illinois
Stretched/ aligned polymers
Poor transverse thermal conductivity
- Reduce material costs: hybrid metal-polymer - Ease of manufacturing scalability
Good heat spreaders
kin-plane ~ 62- 200 Wm-1K-1
keff ~ 2 Wm-1K-1
Transverse elastic moduli 15 %
Xu et al., Nat. Comms. (2019)
Why shear strength > 0.1 MPa is enough?
University of Illinois 19
For a 0.1 MPa joint shear & tensile strength:
At high internal pressures, the joint surfaces move, causing delamination:
Simulated using cohesive zone modelling (CZM)
Safe maximum internal pressure ~ 50 psi (0.3 MPa),
Joint shear/tensile strength of ~0.1 MPa is enough
for a 50 psi water flow
ASME IMECE - 10621 | Nov 12, 2019
Takeaway
Further, we anticipate only a maximum of 3-5 psi absolute pressure during parallel
operation
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Glimpses of related work
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Controls & Health Monitoring
Model trained on data
Heat Exchanger Tube
Learning Module
+
-
Feedback Controller
Heat Exchanger condition Cj
• Objective- Design controls architecture for low cost waste heat recovery heat exchangers:− typically result in reference tracking/regulation problems − e.g. regulate flue gas outlet temperature (𝑇𝑇𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓) by control of flow rate (𝑓𝑓𝑤𝑤)
• Key Challenges- Unmodeled dynamics, large uncertainties and noise− uncertainties in flue gas conditions (e.g. flow rates and temperatures)− unknown/complex system dynamics
• Approach- Learn from historical data− Learn steady state controller operating points (slow-time scale)− Real-time feedback controller for accurate temperature regulation
𝑇𝑇𝑠𝑠𝑠𝑠𝑓𝑓∆𝑡𝑡𝑓𝑓𝑓𝑓
∆𝑡𝑡𝑓𝑓𝑓𝑓
𝑓𝑓𝑤𝑤
ASME IMECE - 10621 | Nov 12, 2019University of Illinois
Comparison of Flow Passing Two Tubes
22
Temperature contour / R2R tube Temperature contour / Smooth tube
Turbulence kinetic energy contour / R2R Turbulence kinetic energy contour / Smooth
Longer recirculation length
More extreme temperature difference
University of Illinois 23
Anti-fouling Coatings
Surface Energy, γp-sub [mJ/m2]
Nuc
leat
ion
Rat
e,
J [m
-2s-1
]
0 10 20 30 40 505x1001x101
1x102
1x103
1x104
1x105
1x106
N = 1x106
N = 5x105
N = 1x105
N = 5x104
N = 1x104
Lower Surface Energy
Smoother Surface
Anti-Fouling(Hydrophobic
and LIS)
SLIPS or LIS
𝑅𝑅 = 𝑁𝑁𝑆𝑆𝑍𝑍𝑍𝑍exp−∆𝐺𝐺𝑘𝑘𝐵𝐵𝑇𝑇
Classical Nucleation Theory
∆𝐺𝐺 =43
𝜋𝜋𝑟𝑟3∆𝑔𝑔 + 4𝜋𝜋𝑟𝑟2𝜎𝜎 SOCAL
ASME IMECE - 10621 | Nov 12, 2019
Acknowledgements
ASME IMECE - 10621 | Nov 12, 2019University of Illinois 24
DOE Award No. DE-EE0008312
Dr. Nenad Miljkovic Dr. Placid Ferreira
Dr. Chenhui Shao Dr. Srinivasa Salapaka
Dr. Sanjiv Sinha(lead PI)
Other aspects: Controls & health monitoring,
HX Simulations,