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Mechanical Properties of Cold Gas Dynamic-Sprayed Near-Net-Shaped Fin Arrays

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Abstract

This work focuses on the study of the adhesion and thermal performance of near-net-shaped pyramidal fin arrays manufactured by cold spray on aluminum alloy substrate coated with various bond coats: a cold-sprayed bond coat as well as nitrogen- and air-propelled arc-sprayed bond coats. Furthermore, the effects of the fin density, fin height, and substrate surface roughness on the adhesion strength of the fins deposited on Al6061 substrates were characterized. It was found that the fin density, the fin height, and the substrate roughness have little impact on the adhesion strength of this system. The adhesion strength was found to be inversely proportional to the surface hardness when investigating these parameters for the different thermal-spray bond coatings, with all the fin systems having a much greater strength than the theoretical application stresses. Finally, it was found that the increase in the fin’s base layer’s roughness increases the overall heat transfer, with the bond coat material having a negligible effect on the thermal resistance for this type of heat-exchanger configuration.

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Abbreviations

\(\Delta P_{\text{fin}}\) :

Fin differential pressure [Pa]

\(\Delta T_{1}\) :

Inlet temperature difference [K]

\(\Delta T_{2}\) :

Outlet temperature difference [K]

\(\Delta T_{\text{lm}}\) :

Log mean temperature difference [K]

\(\varepsilon\) :

Relative surface roughness

\(\eta\) :

Fan efficiency

\(\rho\) :

Fluid density [kg/m3]

\(\tau_{\text{d}}\) :

Fluid drag shear stress [Pa]

\(A_{\text{base}}\) :

Base area [m2]

\(A_{\text{cond}}\) :

Conduction area [m2]

\(A_{\text{conv}}\) :

Convection area [m2]

\(A_{\text{front}}\) :

Frontal area [m2]

\(C_{\text{d}}\) :

Drag coefficient

\({\text{Cp}}\) :

Fluid’s specific heat capacity \([ {\text{kJ/(kg}} \, {\rm{K}})]\)

\(D_{\text{h}}\) :

Hydraulic diameter [m]

\(e_{\text{v}}\) :

Pumping power per unit volume [kW/m3]

\(H\) :

Fin height [m]

\(h\) :

Convective heat-transfer coefficient [W/(m2 · K)]

\(k\) :

Thermal conductivity [W/(m · K)]

\(L\) :

Base length (streamwise direction) [m]

\(\dot{m}\) :

Mass-flow rate [kg/s]

\(q\) :

Heat flux [W/m2]

\(R_{\text{cond}}\) :

Conduction thermal resistance [K/W]

\(R_{\text{conv}}\) :

Convection thermal resistance [K/W]

\(R_{\text{eq}}\) :

Equivalent thermal resistance [K/W]

\(r\) :

Surface roughness [m]

\(T_{\text{in}}\) :

Inlet fluid temperature [K]

\(T_{\text{out}}\) :

Outlet fluid temperature [K]

\(t\) :

Conduction length [m]

\(U\) :

Fluid velocity [m/s]

\({\text{UA}}_{\text{conv}}\) :

Convection thermal conductance [W/K]

\({\text{UA}}_{v}\) :

Thermal conductance per unit volume \([ {\text{kW/(m}}^{ 3} {\text{ K)]}}\)

\(V\) :

Volume [m3]

\(\dot{V}_{f}\) :

Volumetric flow rate [m3/s]

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Acknowledgment

The authors would like to thank the MITACS Accelerate program for the financial support to this project.

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Authors and Affiliations

  1. Mechanical Engineering, University of Ottawa, Ottawa, ON, Canada

    Yannick Cormier, Philippe Dupuis & Bertrand Jodoin

  2. Brayton Energy Canada, Gatineau, QC, Canada

    Antoine Corbeil

Authors
  1. Yannick Cormier
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  2. Philippe Dupuis
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  3. Bertrand Jodoin
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  4. Antoine Corbeil
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Correspondence to Yannick Cormier.

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Cormier, Y., Dupuis, P., Jodoin, B. et al. Mechanical Properties of Cold Gas Dynamic-Sprayed Near-Net-Shaped Fin Arrays. J Therm Spray Tech 24, 476–488 (2015). https://doi.org/10.1007/s11666-014-0203-1

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  • DOI: https://doi.org/10.1007/s11666-014-0203-1

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