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Desenvolvimento do Processo Friction Stir Channeling à Microescala
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A literatura existente revela uma lacuna na pesquisa abrangente sobre os limites de processamento do processo Friction Stir Channeling (FSC), especialmente na criação dos menores
canais contínuos e integrais usando ferramentas com pinos roscados de 2 mm de diâmetro ou
menos. Este estudo está na vanguarda da investigação dos limites extremos do processo FSC
em microescala, que representa promessas significativas para o desenvolvimento de trocado-
res de calor ultracompactos visando melhorar sua eficiência e sustentabilidade. Para atingir
isso, ferramentas personalizadas com dimensões e geometrias específicas foram desenvolvidas
para definir parâmetros que produzem microcanais contínuos de forma confiável, otimizando
o diâmetro hidráulico dentro dos limites do projeto e da geometria de cada ferramenta. Avaliações rigorosas, incluindo testes de continuidade, estanqueidade, micro tomografia computadorizada, tomografia computadorizada de nêutrons, microdureza e desempenho térmico,
foram realizadas para verificar a integridade estrutural e a aplicabilidade dos canais para sistemas de aquecimento e resfriamento supercompactos. Ensaios experimentais foram realizados
utilizando ferramentas com diâmetros de pino de 0,2, 0,3, 0,5, 1,0 e 2,0 mm. A fabricação bem sucedida de canais internos foi obtida com pinos de 0,5, 1,0 e 2,0 mm de diâmetro, combinados
com diâmetros de shoulder correspondentes de 3,5, 4,0 e 5,0 mm, respectivamente. Os experimentos foram conduzidos em placas da liga de alumínio AW1050-H111 com espessura de 5mm. Notavelmente, o menor canal atingiu um diâmetro hidráulico de 191 μm com um pino roscado de 0,5 mm de diâmetro, classificando-o como um microcanal. Além disso, a eficiência térmica de um modelo compacto de trocador de calor foi avaliada, indicando que, apesar dos altos custos associados à produção das ferramentas especializadas, o processo FSC é um método viável, confiável e repetível para a fabricação de mini e microcanais.
Existing literature reveals a gap in comprehensive research on the processing limits of the Friction Stir Channeling (FSC) process, especially in the creation of the smallest continuous and integral channels using tools with threaded probes of 2 mm diameter or smaller. This study is at the forefront of investigating the extreme boundaries of the microscale FSC process, which holds significant promises for the development of ultra-compact heat exchangers aimed at improving their efficiency and sustainability. To achieve this, customized tools with specific dimensions and geometries were developed to set parameters that reliably yield continuous microchannels, optimizing the hydraulic diameter within the limits of each tool's design and geometry. Rigorous assessments, including tests for continuity, watertightness, micro-computed tomography, neutron computed tomography, microhardness, and thermal performance, were carried out to verify the structural integrity and applicability of the channels for super compact heating and cooling systems. Experimental trials were conducted using tools with probe diameters of 0.2, 0.3, 0.5, 1.0, and 2.0 mm. Successful fabrication of internal channels was achieved with the probes of 0.5, 1.0, and 2.0 mm in diameter, combined with corresponding shoulder diameters of 3.5, 4.0, and 5.0 mm, respectively. The experiments were carried out on AW1050-H111 aluminum alloy plates with a thickness of 5 mm. Notably, the smallest channel achieved a hydraulic diameter of 191 μm with a 0.5 mm diameter threaded probe, classifying it as a microchannel. Furthermore, the thermal efficiency of a compact heat exchanger model was evaluated, indicating that despite the high costs associated with the production of the specialized tools, the FSC process is a feasible, dependable, and repeatable method for manufacturing mini-and microchannels.
Existing literature reveals a gap in comprehensive research on the processing limits of the Friction Stir Channeling (FSC) process, especially in the creation of the smallest continuous and integral channels using tools with threaded probes of 2 mm diameter or smaller. This study is at the forefront of investigating the extreme boundaries of the microscale FSC process, which holds significant promises for the development of ultra-compact heat exchangers aimed at improving their efficiency and sustainability. To achieve this, customized tools with specific dimensions and geometries were developed to set parameters that reliably yield continuous microchannels, optimizing the hydraulic diameter within the limits of each tool's design and geometry. Rigorous assessments, including tests for continuity, watertightness, micro-computed tomography, neutron computed tomography, microhardness, and thermal performance, were carried out to verify the structural integrity and applicability of the channels for super compact heating and cooling systems. Experimental trials were conducted using tools with probe diameters of 0.2, 0.3, 0.5, 1.0, and 2.0 mm. Successful fabrication of internal channels was achieved with the probes of 0.5, 1.0, and 2.0 mm in diameter, combined with corresponding shoulder diameters of 3.5, 4.0, and 5.0 mm, respectively. The experiments were carried out on AW1050-H111 aluminum alloy plates with a thickness of 5 mm. Notably, the smallest channel achieved a hydraulic diameter of 191 μm with a 0.5 mm diameter threaded probe, classifying it as a microchannel. Furthermore, the thermal efficiency of a compact heat exchanger model was evaluated, indicating that despite the high costs associated with the production of the specialized tools, the FSC process is a feasible, dependable, and repeatable method for manufacturing mini-and microchannels.
Descrição
Palavras-chave
Micro Friction Stir Channeling (μFSC) microcanais internos canais contínuos limites do processo diâmetro hidráulico