Experimental investigation of heat transfer through porous media in superfluid helium

An experimental investigation of heat transfer through porous media in superfluid helium has been conducted in the framework of the development of porous electrical insulations for superconducting magnet cables cooled by superfluid helium. Several types of porous media with different characteristics were tested and, in particular, samples with pore size diameters of 0.1 μm, 1 μm, 2 μm, 10 μm and 20 μm. Temperature and pressure were measured between an insulating inner bath and the cryostat bath, communicating only through the porous medium. The cryostat bath is held constant all along the measurement and, for each sample, the tests are performed for bath temperature from 1.4 K to 2.1 K with 0.1 K increment. Depending on the porous medium average pore size diameter, different flow regimes are observed: for porous media with a pore diameter of 0.1 and 1 μm, only the Landau regime is observed whereas for porous media with a pore diameter of 2 μm, we observed the Landau regime and the Gorter-Mellink regime. For samples with a pore diameter of 10 and 20 μm, measurements only permitted to detect the Gorter-Mellink regime. In the laminar regime, the permeability of the samples was determined and it was found that the permeability is constant for bath temperature above 1.9 K whereas it increases as the bath temperature decreases from 1.8 K to 1.4 K. For samples with a pore size diameter of 10 and 20 μm, measurement permits only to observe the turbulent regime and the analysis exhibits a constant average tortuosity for each samples, independently of the bath temperature.     

Pressure drop reduction and heat transfer deterioration of slush nitrogen in triangular and circular pipe flows

Slush fluids such as slush hydrogen and slush nitrogen are characterized by superior properties as functional thermal fluids due to their density and heat of fusion. In addition to allowing efficient hydrogen transport and storage, slush hydrogen can serve as a refrigerant for high-temperature superconducting (HTS) equipment using MgB₂, with the potential for synergistic effects. In this study, pressure drop reduction and heat transfer deterioration experiments were performed on slush nitrogen flowing in a horizontal triangular pipe with sides of 20 mm under the conditions of three different cross-sectional orientations. Experimental conditions consisted of flow velocity (0.3–4.2 m/s), solid fraction (0–25 wt.%), and heat flux (0, 10, and 20 kW/m²). Pressure drop reduction became apparent at flow velocities exceeding about 1.3–1.8 m/s, representing a maximum amount of reduction of 16–19% in comparison with liquid nitrogen, regardless of heating. Heat transfer deterioration was seen at flow velocities of over 1.2–1.8 m/s, for a maximum amount of deterioration of 13–16%. The authors of the current study compared the results for pressure drop reduction and heat transfer deterioration in triangular pipe with those obtained previously for circular and square pipes, clarifying differences in flow and heat transfer properties. Also, a correlation equation was obtained between the slush Reynolds number and the pipe friction factor, which is important in the estimation of pressure drop in unheated triangular pipe. Furthermore, a second correlation equation was derived between the modified slush Reynolds number and the pipe friction factor, enabling the integrated prediction of pressure drop in both unheated triangular and circular pipes.     

Experimental measurements and modeling of transient heat transfer in forced flow of He II at high velocities

An experiment has been built to study heat transfer in forced flow of He II at flow velocities up to 22 m/s. The main part of this experiment is a 10 mm ID, 0.86 m long straight test section instrumented with a heater, thermometers and pressure transducers. The high flow velocities allow clear observation of the effects of the forced convection, counterflow heat transfer and the Joule–Thomson effect. A numerical model based on the He II energy conservation equation and including pressure effects has been developed to compare with the experimental results. The model works well for low flow velocities where the heat flux is primarily driven by the temperature gradient and for high flow velocities where the heat flux is primarily driven by the pressure gradients. In the intermediate velocity region, discrepancies between the model and experiment may result from an inappropriate representation of the heat flux by counterflow when the temperature and pressure gradients have an effect of similar magnitude on the heat flux.     

Evaluation of microstructure and mechanical properties in friction stir processed SKD61 tool steel

A SKD61 tool steel was friction stir processed using a polycrystalline cubic boron nitride tool. Microstructure, tensile properties and wear characteristic were evaluated. Fine grains with a martensite structure were produced in the friction stir processed zone, which led to the increase of the microindentation hardness. The grains became finer when the heat input was lowered. The transverse tensile strength of the friction stir processed zone was equal to that of base metal and all the tensile specimens fractured at base metal zone. The wear width and depth of the friction stir processed zone at the load of 1.96 N were 339 μm and 6 μm, as compared to 888 μm and 42 μm of the base metal, decreased by 62% and 86%. Findings of the present study suggest that low heat input is an effective method to produce a friction stir processed zone composed of relatively fine grain martensitic structure with good tensile properties and wear characteristic.     

Pressure drop of slush nitrogen flow in converging–diverging pipes and corrugated pipes

Cryogenic slush fluids such as slush hydrogen and slush nitrogen are solid–liquid, two-phase fluids. As a functional thermal fluid, there are high expectations for use of slush fluids in various applications such as fuels for spacecraft engines, clean-energy fuels to improve the efficiency of transportation and storage, and as refrigerants for high-temperature superconducting equipment. Experimental flow tests were performed using slush nitrogen to elucidate pressure-drop characteristics of converging–diverging (C–D) pipes and corrugated pipes. In experimental results regarding pressure drop in two different types of C–D Pipes, i.e., a long-throated pipe and a short-throated pipe, each having an inner diameter of 15 mm, pressure drop for slush nitrogen in the long-throated pipe at a flow velocity of over 1.3 m/s increased by a maximum of 50–60% as compared to that for liquid nitrogen, while the increase was about 4 times as compared to slush nitrogen in the short-throated pipe. At a flow velocity of over 1.5 m/s in the short-throated pipe, pressure drop reduction became apparent, and it was confirmed that the decrease in pressure drop compared to liquid nitrogen was a maximum of 40–50%. In the case of two different types of corrugated pipes with an inner diameter of either 12 mm or 15 mm, a pressure-drop reduction was confirmed at a flow velocity of over 2 m/s, and reached a maximum value of 37% at 30 wt.% compared to liquid nitrogen. The greater the solid fractions, the smaller the pipe friction factor became, and the pipe friction factor at the same solid fraction showed a constant value regardless of the Reynolds number. From the observation of the solid particles’ behavior using a high-speed video camera and the PIV method, the pressure-drop reduction mechanisms for both C–D and corrugated pipes were demonstrated.     

Pressure drop and heat transfer during two-phase flow vaporization of propane in horizontal smooth minichannels

This study examined the two-phase flow boiling pressure drop and heat transfer for propane, as a long term alternative refrigerant, in horizontal minichannels. The pressure drop and local heat transfer coefficients were obtained for heat fluxes ranging from 5–20 kW m^?2, mass fluxes ranging from 50–400 kg m^?2 s^?1, saturation temperatures of 10, 5 and 0 °C, and quality up to 1.0. The test section was made of stainless steel tubes with inner diameters of 1.5 mm and 3.0 mm, and lengths of 1000 mm and 2000 mm, respectively. The present study showed the effect of mass flux, heat flux, inner tube diameter and saturation temperature on pressure drop and heat transfer coefficient. The experimental results were compared against several existing pressure drop and heat transfer coefficient prediction methods. Because the study on evaporation with propane in minichannels was limited, new correlations of pressure drop and boiling heat transfer coefficient were developed in this present study.     

Studies on the processing of nickel base porous wicks for capillary pumped loop for thermal management of spacecrafts

Nickel base sintered porous wicks have potential application as capillary structure in two-phase heat transfer loops of a heat dissipation system, like capillary pumped loop (CPL) and loop heat pipe (LHP). A porous wick is located inside the evaporator of the CPL system and it transports working fluid in the loop by capillary action.In the present work, experimental trials were carried out to achieve porous wick having high porosity with interconnected pores of average size less than 5 μm, higher aspect ratio (L/D >10) and permeability better than 10 m-Darcy (10^?14 m²). A carbonyl nickel powder (2–7 μm) was used as raw material. Loose carbonyl nickel powders (2–7 μm) were sintered in graphite mould under hydrogen atmosphere at different temperatures in order to optimize porosity, pore size and permeability of the sintered wick. For mechanical and physical properties characterization, samples were cut from sintered rod using EDM wire cut to avoid pore closure. Profile making on the sintered rod is also done by wire EDM. Microstructural characterization as well as the effect of W-EDM on the surface pores was done using Scanning Electron Microscopy (SEM). Surface profile making through W-EDM had shown encouraging result. After optimization of process parameters cylindrical wick (L/D ratio: 10) with porosity of 64%, average pore size of 5 μm and a permeability of 70 m-Darcy could be realized.The present paper explain the details of processing of cylindrical shaped porous wicks through sintering technique and effect of EDM on surface pores characteristic.     

Modeling of a horizontal circulation open loop in two-phase helium

In the process of the cryogenic cooling system design of the superconducting magnet of the R³B spectrometer, heat and mass transfer in a two-phase He I natural circulation loop with a horizontal heated section has been investigated experimentally. The experiments were conducted on a 2 m high experimental loop with a copper tube of 10 mm inner diameter uniformly heated over a length of 4 m. All data were obtained near atmospheric pressure. Evolution of the mass flow rates as a function of heat flux in steady state condition are presented and compared to a numerical model that have been developed to assist the design of such a cooling scheme. The model is based on a one-dimensional equations system, which includes mass, momentum and energy balances. It is based on the homogeneous model with a specific friction coefficient for the horizontal heated section. The model reproduces with an acceptable accuracy the experimental results and now serves as a tool for the design.     

Thermal and hydrodynamic considerations of ice slurry in heat exchangers

This article focuses on the behavior in heat exchangers of an ice slurry composed of fine ice particles inside an ethanol–water solution. The heat transfer and friction characteristics were studied in two double pipe heat exchangers, one with a smooth surface and another with an improved surface. Heat transfer coefficients and pressure drops were experimentally investigated for the slurry flowing in the internal tube with ice mass fractions ranging from 0 to 30% and with flow velocities between 0.3 and 1.9 m s^?1. For some flow velocities, the results showed that an increase in the ice fractions caused a change in the slurry flow structure influencing the evolution of the pressure drops and the heat transfer coefficients. Critical ice fraction values were determined corresponding to a change flow structure from laminar to turbulent motion revealed by the evolution of the friction factor.     

Manipulation and welding of metal spheres above 10 μm using needle-like probe

A needle-like probe is the simplest tool to manipulate fine spheres. It catches fine spheres by adhesion forces without any holding device. Metallic spheres of 10–100 μm are difficult to manipulate with the needle-like probe, because the gravity rivals the adhesion forces in the dynamics of the spheres. Large and heavy spheres arranged on a substrate are easily disturbed because of the same reason. Here, a manipulator equipped with a direct power source, which applies voltage to the probe, is fabricated. Large and heavy spheres are adhered by the controllable electrostatic force. Besides the manipulation, the apparatus is designed to weld the spheres by using the probe as electrode for spot/arc welding. Experiments on the manipulation showed that the probe caught gold spheres of 40–80 μm by applying 20–50 V and released by putting them down after cutting the power off. Following to manipulation, welding experiments were carried out at various conditions. Two power sources, a high-voltage and low-current power source and a low-voltage and high-current power source, and two welding methods, arc welding and spot welding, are examined. The experiments showed that the gold spheres of 40–80 μm can be welded by the spot welding using the high-voltage and low-current power source, of which maximum power rating is 10 kV×1 mA. The probe is kept to touch the sphere and 4 kV or more is applied. Electric sparks are generated at the interface of the probe and the substrate, and the sphere is welded to the substrate. In both the manipulation and welding, the contact pressure must be very low. A tower of gold spheres is fabricated as an example of three-dimensional microstructures composed of fine spheres.     

Effects of biofouling on air-side heat transfer and pressure drop for finned tube heat exchangers

Experimental investigations on the effects of biofouling on air-side heat transfer and pressure drop for three biofouled finned tube heat exchangers and one clean finned tube heat exchanger were performed. Artificial accelerated method of microorganism growth on the fin surface was used for simulating the biofouled finned tube heat exchangers. Experimental results indicate that the effects of biofouling on the air-side heat transfer coefficient decreases 7.2% at 2.0 m/s when the biofouled area ratio is 10%, while it decreases 15.9% at 2.0 m/s when the biofouled area ratio is 60%, and biofouling causes a 21.8% ～ 41.3% increase in pressure drop when the air velocity is between 0.5 and 2.0 m/s. The increase of inlet air velocity is helpful to improve the long-term performance of finned tube heat exchanger. Biofouling makes the hydrophilic coating failure, and the condensation water easily converges on the fin surface where biofouling grows.     

Development of porous plug phase separator and superfluid film flow suppression system for the Soft X-ray Spectrometer onboard ASTRO-H

ASTRO-H is the sixth Japanese astronomy satellite scheduled for launch in 2014. The Soft X-ray Spectrometer instrument is onboard ASTRO-H. This is a 6 × 6 array of X-ray microcalorimeters with an energy resolution of <7 eV at 0.5–10 keV. Superfluid liquid helium is utilized as a part of the cooling system. To retain the liquid helium in the tank under zero-gravity, a porous plug phase separator made of sintered stainless is used. Since the vapor mass flow rate is only 29 μg/s, any additional superfluid film loss influences the lifetime of the liquid helium. Therefore, a film flow suppression system consisting of an orifice, a heat exchanger, and knife edge devices is adopted based on the design used for the X-ray Spectrometer onboard Suzaku. The film flow will be suppressed to <2 μg/s, sufficiently smaller than the vapor flow rate. In the present investigation, the design and ground experiments of a helium vent system composed of the porous plug and film flow suppression system are presented. The results show that the phase separation and the film flow suppression are satisfactorily achieved.     

Determination of laminar and turbulent flow ranges through vertical packed beds in terms of particle friction factors

Despite the presence of a variety of studies dealing with the magnitude of particle Reynolds number, Re_p defining transition from laminar to turbulent regime for flow through packed beds, the manner is still one of the unknowns. An approach based on the experimental data concerning upward airflow through fixed cylindrical packed beds is presented in this paper. The utilized packed beds had the following ranges of; sphericity, Φ, 0.55 ? Φ ? 1.00, packing material diameter to bed length ratio, D_p/L, 0.04 ? D_p/L ? 0.72, and bed porosity, ε, 0.36 ? ε ? 0.56. The test cases covered the ranges of particle Reynolds number, Re_p 708 ? Re_p ? 7772 and particle Froude number; Fr_p 2.86 ? Fr_p ? 10.39. The measurements of pressure drop through packed bed; ΔP_Bed and superficial mean exit velocity; U are used to determine bed frictional effects in reference to the available literature on particle friction factors, f_p. The magnitude of Re_p defining transition is assumed to be 2000 with particular emphasis to the flow dynamics. The definitions of Bird et al. [R.B. Bird, W.E. Stewart, E.N. Lightfoot, Transport Phenomena, John Wiley and Sons, NY, 1960] are used to calculate f_p. The calculated f_p for the covered test cases are given as a function of pressure coefficient, ΔP* and Re_p, Fr_p, Φ, ε, D_p/L in the approximate ranges of laminar and turbulent flow for Re_p < 2000 and Re_p > 2000, respectively. The proposed separate equations of f_p = f_p(ΔP*, Re_p, Fr_p, Φ, ε, D_p/L) are satisfied for laminar and turbulent flows with corresponding average error margins of ±7.6% and ±18%. Furthermore ranges of transitional and fully rough flow through packed beds are estimated as 2000 ? Re_p ? 4000 and Re_p > 5000 with an analogy to the well-known Moody Chart in pipe flows.     

Pressure drop correlation for oil–refrigerant R134a mixture flashing flow in a small diameter tube

This paper presents an experimental investigation of the ester oil ISO VG10/refrigerant R134a mixture flashing flow in a 6.0 m long, 3.22 mm ID tube, which is one of the primary steps towards the construction of a methodology for the study of the lubrication and gas leakage in refrigeration compressors. The phase change starts with solubility reduction of the refrigerant in the oil as the pressure decreases due to the friction forces. In this flashing flow the foam pattern is observed at the end of the tube as vapor quality reaches high values, and this is a particular phenomenon of this kind of mixture flow. In order to study this pressure drop, an experimental apparatus was designed to allow the measurement of both pressure and temperature profiles along the tube as well as the visualization of the flow patterns. Pressure and temperature distribution along the flow were measured for saturation pressure ranging from 450 to 650 kPa, mass flux ranging from about 2000 to 3000 kg/(m²s), temperatures around 303 K, and inlet refrigerant concentration varying between 0.2 and 0.4 kg ref/kg mixt. An available correlation proposed to predict the frictional pressure drop for a mixture composed by the mineral oil SUNISO 1GS and refrigerant R12 flowing in small diameter tubes yielded large deviations in predicting the ester oil and refrigerant R134a mixture flow. A new correlation has been proposed that fitted the experimental data with rms deviations of 24%.     

Highly porous ZnS microspheres for superior photoactivity after Au and Pt deposition and thermal treatment

This work highlights the enhanced photocatalytic activity of porous ZnS microspheres after Au and Pt deposition and heat treatment at 500 °C for 2 h. Microporous ZnS particles of size 2–5 μm with large surface area 173.14 m² g⁻¹ and pore volume 0.0212 cm³ g⁻¹ were prepared by refluxing under an alkaline medium. Photoluminescence of ZnS at 437 nm attributed to sulfur or zinc vacancies were quenched to 30% and 49%, respectively, after 1 wt% Au and Pt loading. SEM images revealed that each ZnS microparticle consist of several smaller ZnS spheres of size 2.13 nm as calculated by Scherrer's equation. The rate of photooxidation of 4-nitrophenol (10 μM) under UV (125 W Hg arc–10.4 mW/cm²) irradiation has been significantly improved by Au and Pt deposition followed by sintering due to better electron capturing capacity of deposited metals and growth of crystalline ZnS phase with less surface defects.     

Multi-layered adsorption of 3Y–ZrO2 nanoparticles on polystyrene microsphere

Multi-layered adsorption of 3Y–ZrO₂ nanoparticles on polystyrene (PS) microsphere using layer-by-layer (LBL) assembly technique was investigated. By employing sodium poly (acrylic acid) (PAANa) and polyethylenimine (PEI) to modify the zeta potential of the powders, the heterocoagulation takes place between the coating powders and microspheres substrate and the zirconia coating on the surface of polystyrene spheres was successfully formed. Dense, uniform multi-layered zirconia can be obtained on the surface of polystyrene spheres and the thickness of zirconia coating increased by repeating the coating process. The diameter of the spheres expands to 1.5 μm after the first coating and 1.65 μm after the third coating comparing with the original polystyrene spheres with diameter of 1.4 μm.     

Measurement and correlation of frictional pressure drop of refrigerant-based nanofluid flow boiling inside a horizontal smooth tube

The objective of this paper is to investigate the effect of nanoparticle on the frictional pressure drop characteristics of refrigerant-based nanofluid flow boiling inside a horizontal smooth tube, and to present a correlation for predicting the frictional pressure drop of refrigerant-based nanofluid. R113 refrigerant and CuO nanoparticle were used for preparing refrigerant-based nanofluid. Experimental conditions include mass fluxes from 100 to 200 kg m^?2 s^?1, heat fluxes from 3.08 to 6.16 kW m^?2, inlet vapor qualities from 0.2 to 0.7, and mass fractions of nanoparticles from 0 to 0.5 wt%. The experimental results show that the frictional pressured drop of refrigerant-based nanofluid increases with the increase of the mass fraction of nanoparticles, and the maximum enhancement of frictional pressure drop is 20.8% under above conditions. A frictional pressure drop correlation for refrigerant-based nanofluid is proposed, and the predictions agree with 92% of the experimental data within the deviation of ±15%.     

Effect of twisted tape insert on heat transfer and pressure drop in horizontal evaporators for the flow of R-134a

An experimental study has been carried out on the heat transfer enhancement and pressure drop characteristics in presence of twisted tape inserts, during flow boiling of R-134a, inside a horizontal evaporator. The test-evaporator was an electrically heated 1260 mm long copper tube with 7.5 mm inside diameter. The experiments were performed for plain flow and four tubes with twisted tapes of 6, 9, 12 and 15 twist ratios and four refrigerant mass velocities of 54, 85, 114 and 136 kg/s m² for each tape. It has been found that the twisted tape inserts enhance the heat transfer coefficient on relatively higher pressure drop penalty, in comparison to that for the plain flow.     

Erosion in the tube entrance region of an air-cooled heat exchanger

Erosion in the tube entrance region of a typical air-cooled heat exchanger is numerically predicted. The erosion rates are obtained for different flow rates and particle sizes assuming low particle concentration. The erosion prediction is based on using a mathematical model for simulating the fluid velocity field and another model for simulating the motion of solid particles. The fluid velocity model is based on the solution of the time-averaged governing equations of 3-D turbulent flow while the particle-tracking model is based on the solution of the governing equation of each particle motion taking into consideration the viscous and gravity forces as well as the effect of particle rebound behavior. The computational model was validated against available experimental data and the comparison resulted in a good agreement. The investigation covered particle sizes from 10 to 350 μm and inlet flow velocities from 0.18 to 4.5 m/s. The results show that the location and number of eroded tubes depend mainly on the particle size and flow velocity at the header inlet. The total rate of erosion was found to increase exponentially with flow velocity. At high flow velocities, the maximum total erosion rate results from large particles and the effect is reversed at low velocities. Similarly, the tube penetration rate was found to increase with the increase of flow velocity for all particle sizes. At the typical velocity of 1.1 m/s, the minimum tube lifetime was caused by the 350 μm particles and the maximum was caused by the 200 μm particles. Based on the obtained results, it is well established that erosion cannot be totally avoided so long as solid particles are present in the fluid. However, the threshold velocity below which erosion is negligible can be accurately defined if an acceptable lifetime (or penetration rate) is defined.     

Wavelet packet analysis of particle response to turbulent fluctuation

The fluid–particle synchronous measurements in a boundary layer wind tunnel were conducted to determine the particle concentration response to turbulent velocity fluctuation. Three groups of natural sand samples (diameter of 300–500, 100–125 and 63–80 μm) were employed in the experiments. Consecutive instants of saltating particles were recorded by using a high-speed digital camera at 2000 frames per second and a constant-temperature hot-wire anemometer was used to measure the turbulent fluctuation simultaneously. The particle concentration in the saltation layer was calculated by the dynamic-threshold binarization algorithm. The results confirm that the concentration fluctuation is a fairly typical stochastic process, and the low-frequency variation of particle concentration is closely related to the turbulent fluctuation. Moreover, a method was developed to apply wavelet packet transform to two-phase data analysis from the viewpoint of frequency-domain energy structure. Further analysis shows that the concentration fluctuation is predominant in the low frequency band less than 250 Hz. In addition, the particle concentration response to the turbulent fluctuation is significantly correlated with the particle diameter. For the fine particles (63–80 μm), medium particles (100–125 μm) and coarse particles (300–500 μm), the highest response frequencies of particle concentration variation to the turbulent fluctuation are 60, 40 and 30 Hz, respectively, which demonstrates that an appropriate sampling rate is crucial in saltation measurement. These qualitative and quantitative results are beneficial to understand the fluid–particle interaction mechanism.