Micro-manufacturing of micro-scale porous surface structures for enhanced heat transfer applications: An experimental process optimization study

Ömer N. Cora, Yusuf Usta, Muammer Koç

Research output: Contribution to journalArticle

21 Citations (Scopus)

Abstract

Integrated and compact products necessitate the use of advanced thermal management systems with reduced footprint and cost as well as increased efficiency. Micro-scale, porous and modulated (i.e. channels, pyramids, etc) surfaces offer increased surface area for a given volume and lead to two-phase heat transfer conditions with efficiency enhancements up to 300%. Such surfaces made of copper powders were demonstrated to be quite effective by several researchers after they were produced in controlled lab environments. Similar surfaces made of high temperature resistant materials such as stainless steel, nickel and titanium can also be used in fuel processor, SOFC and PEM fuel cell applications as bipolar/interconnect plates. However, their fabrication under mass-production conditions for marketable and cost-effective products requires well-established process parameters. In this study, warm compaction of copper powders onto thin copper solid substrates was experimented with under different compaction pressure (15-50 MPa), temperature (350-500 °C) and surface geometry (flat, large and small channeled) parameters using a design of experiment (DOE) approach to determine the proper process conditions. Porosity and bonding strength of compacted samples were measured to characterize their feasibility for compact and/or micro-scale heat/mass transfer applications. Results showed that a minimum 350 °C temperature and 15 MPa pressure level is necessary to obtain sound porous and micro-channeled surface layers. It was also found that at higher pressure levels (50 MPa), fabrication of micro-scale surface structures is highly repeatable with enhanced bonding strength characteristics. DOE findings will be used to establish proper process conditions to produce such porous surfaces using a continuous roll compaction process in the future.

Original languageEnglish
Article number045011
JournalJournal of Micromechanics and Microengineering
Volume19
Issue number4
DOIs
Publication statusPublished - 2009
Externally publishedYes

Fingerprint

Surface structure
Heat transfer
Copper powder
Compaction
Design of experiments
Fabrication
Stainless Steel
Titanium
Solid oxide fuel cells (SOFC)
Nickel
Temperature control
Temperature
Costs
Fuel cells
Copper
Mass transfer
Stainless steel
Porosity
Acoustic waves
Geometry

ASJC Scopus subject areas

  • Electronic, Optical and Magnetic Materials
  • Mechanics of Materials
  • Mechanical Engineering
  • Electrical and Electronic Engineering

Cite this

@article{bb86703aa34841f88d8d7b686109d3a3,
title = "Micro-manufacturing of micro-scale porous surface structures for enhanced heat transfer applications: An experimental process optimization study",
abstract = "Integrated and compact products necessitate the use of advanced thermal management systems with reduced footprint and cost as well as increased efficiency. Micro-scale, porous and modulated (i.e. channels, pyramids, etc) surfaces offer increased surface area for a given volume and lead to two-phase heat transfer conditions with efficiency enhancements up to 300{\%}. Such surfaces made of copper powders were demonstrated to be quite effective by several researchers after they were produced in controlled lab environments. Similar surfaces made of high temperature resistant materials such as stainless steel, nickel and titanium can also be used in fuel processor, SOFC and PEM fuel cell applications as bipolar/interconnect plates. However, their fabrication under mass-production conditions for marketable and cost-effective products requires well-established process parameters. In this study, warm compaction of copper powders onto thin copper solid substrates was experimented with under different compaction pressure (15-50 MPa), temperature (350-500 °C) and surface geometry (flat, large and small channeled) parameters using a design of experiment (DOE) approach to determine the proper process conditions. Porosity and bonding strength of compacted samples were measured to characterize their feasibility for compact and/or micro-scale heat/mass transfer applications. Results showed that a minimum 350 °C temperature and 15 MPa pressure level is necessary to obtain sound porous and micro-channeled surface layers. It was also found that at higher pressure levels (50 MPa), fabrication of micro-scale surface structures is highly repeatable with enhanced bonding strength characteristics. DOE findings will be used to establish proper process conditions to produce such porous surfaces using a continuous roll compaction process in the future.",
author = "Cora, {{\"O}mer N.} and Yusuf Usta and Muammer Ko{\cc}",
year = "2009",
doi = "10.1088/0960-1317/19/4/045011",
language = "English",
volume = "19",
journal = "Journal of Micromechanics and Microengineering",
issn = "0960-1317",
publisher = "IOP Publishing Ltd.",
number = "4",

}

TY - JOUR

T1 - Micro-manufacturing of micro-scale porous surface structures for enhanced heat transfer applications

T2 - An experimental process optimization study

AU - Cora, Ömer N.

AU - Usta, Yusuf

AU - Koç, Muammer

PY - 2009

Y1 - 2009

N2 - Integrated and compact products necessitate the use of advanced thermal management systems with reduced footprint and cost as well as increased efficiency. Micro-scale, porous and modulated (i.e. channels, pyramids, etc) surfaces offer increased surface area for a given volume and lead to two-phase heat transfer conditions with efficiency enhancements up to 300%. Such surfaces made of copper powders were demonstrated to be quite effective by several researchers after they were produced in controlled lab environments. Similar surfaces made of high temperature resistant materials such as stainless steel, nickel and titanium can also be used in fuel processor, SOFC and PEM fuel cell applications as bipolar/interconnect plates. However, their fabrication under mass-production conditions for marketable and cost-effective products requires well-established process parameters. In this study, warm compaction of copper powders onto thin copper solid substrates was experimented with under different compaction pressure (15-50 MPa), temperature (350-500 °C) and surface geometry (flat, large and small channeled) parameters using a design of experiment (DOE) approach to determine the proper process conditions. Porosity and bonding strength of compacted samples were measured to characterize their feasibility for compact and/or micro-scale heat/mass transfer applications. Results showed that a minimum 350 °C temperature and 15 MPa pressure level is necessary to obtain sound porous and micro-channeled surface layers. It was also found that at higher pressure levels (50 MPa), fabrication of micro-scale surface structures is highly repeatable with enhanced bonding strength characteristics. DOE findings will be used to establish proper process conditions to produce such porous surfaces using a continuous roll compaction process in the future.

AB - Integrated and compact products necessitate the use of advanced thermal management systems with reduced footprint and cost as well as increased efficiency. Micro-scale, porous and modulated (i.e. channels, pyramids, etc) surfaces offer increased surface area for a given volume and lead to two-phase heat transfer conditions with efficiency enhancements up to 300%. Such surfaces made of copper powders were demonstrated to be quite effective by several researchers after they were produced in controlled lab environments. Similar surfaces made of high temperature resistant materials such as stainless steel, nickel and titanium can also be used in fuel processor, SOFC and PEM fuel cell applications as bipolar/interconnect plates. However, their fabrication under mass-production conditions for marketable and cost-effective products requires well-established process parameters. In this study, warm compaction of copper powders onto thin copper solid substrates was experimented with under different compaction pressure (15-50 MPa), temperature (350-500 °C) and surface geometry (flat, large and small channeled) parameters using a design of experiment (DOE) approach to determine the proper process conditions. Porosity and bonding strength of compacted samples were measured to characterize their feasibility for compact and/or micro-scale heat/mass transfer applications. Results showed that a minimum 350 °C temperature and 15 MPa pressure level is necessary to obtain sound porous and micro-channeled surface layers. It was also found that at higher pressure levels (50 MPa), fabrication of micro-scale surface structures is highly repeatable with enhanced bonding strength characteristics. DOE findings will be used to establish proper process conditions to produce such porous surfaces using a continuous roll compaction process in the future.

UR - http://www.scopus.com/inward/record.url?scp=68849116779&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=68849116779&partnerID=8YFLogxK

U2 - 10.1088/0960-1317/19/4/045011

DO - 10.1088/0960-1317/19/4/045011

M3 - Article

AN - SCOPUS:68849116779

VL - 19

JO - Journal of Micromechanics and Microengineering

JF - Journal of Micromechanics and Microengineering

SN - 0960-1317

IS - 4

M1 - 045011

ER -