Thermal Spray Forming of High-Efficiency, Metal-Foam Heat Exchanger Tubes
Bibliographic record
Abstract
Abstract Thermal spray coating processes have been employed in the current study to deposit well-adhered, dense skins on the surfaces of open-cell nickel foams. Using foam with 10 and 40 PPI (pores per inch) pore sizes, square channels were made with a height of 20mm and having a length of 250mm. In a unique process that prevents the deposited skin from penetrating the foam substrate via a paste comprised of a thermoset resin and powder particles, a dense stainless steel skin with an average thickness of 400 μm is applied to the exterior of the foam sample. The result is a channel that consists of a Ni foam core and a stainless steel skin wall that can be used as a compact heat-exchanger by directing the coolant flow through the foam. To study the feasibility of the metallic foam heat-exchangers, hydraulic and heat-transfer characteristics were investigated experimentally. The local wall and fluid temperature distribution and the pressure drop along the length of the heat exchanger were measured for heat-flux of 1540.35 – 9627.38 W/m2. Experiments were conducted using air as the coolant and varying flow velocity from 10 – 80 L/min. For non-Darcy flow with inertia effects in the porous media, the Dupuit and Forchheimer modification is employed with the experimental results to determine foam characteristics such as permeability (K), Ergun coefficient (CE) and the friction factor (f). To measure the heat-transfer performance of the metal foam filled channels, a length average Nusselt number is derived based on the local wall and fluid temperatures. Heat transfer was shown to have nearly doubled compared to that of a channel without a foam core.
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How this classification was reachedexpand
Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.000 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.000 | 0.000 |
| Bibliometrics | 0.000 | 0.000 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.000 | 0.000 |
| Open science | 0.000 | 0.000 |
| Research integrity | 0.000 | 0.000 |
| Insufficient payload (model declined to judge) | 0.001 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one teacher head, not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".