TY - GEN
T1 - Joining techniques for novel metal polymer hybrid heat exchangers
AU - Kuntumalla, Gowtham
AU - Meng, Yuquan
AU - Rajagopal, Manjunath
AU - Toro, Ricardo
AU - Zhao, Hanyang
AU - Chan Chang, Ho
AU - Sundar, Sreenath
AU - Salapaka, Srinivasa
AU - Miljkovic, Nenad
AU - Shao, Chenhui
AU - Ferreira, Placid
AU - Sinha, Sanjiv
N1 - Funding Information:
The authors gratefully acknowledge a research award from the Department of Energy, US (DE-EE0008312).
Publisher Copyright:
Copyright © 2019 ASME.
PY - 2019
Y1 - 2019
N2 - In the United States, over 50% of the unrecovered energy from industrial processes is in the form of low-grade heat (<220°C). Materials and maintenance costs of common heat exchangers are typically too high to justify their usage. Polymers, though more affordable, are usually unsuitable for HX applications due to their low thermal conductivity (~0.2 W/mK). Here, we show that metal-polymer hybrids may be attractive from both performance and cost perspectives. The use of polymers further increases the resistance to corrosion by sulfuric and carbonic acids often present in flue gases. An ongoing work explores different configurations of layered polyimide-copper macroscale hybrids for heat exchanger applications using numerical simulations. This paper explores a manufacturing pathway for producing such layered hybrid tubes that involves directly rolling and bonding tapes made of polymer and copper foil into tubes. A critical problem in the fabrication process is the bonding of metal and polymers. We explore approaches involving adhesives (epoxy, acrylic and silicone) for metal/polymer interfaces and direct welding (ultrasonic) for metal/metal interfaces that can be integrated into the manufacturing process. We report characterizations of the thermomechanical properties of these joining processes. This work paves the way for realizing cost-effective manufacturing of heat exchangers for low grade waste heat recovery.
AB - In the United States, over 50% of the unrecovered energy from industrial processes is in the form of low-grade heat (<220°C). Materials and maintenance costs of common heat exchangers are typically too high to justify their usage. Polymers, though more affordable, are usually unsuitable for HX applications due to their low thermal conductivity (~0.2 W/mK). Here, we show that metal-polymer hybrids may be attractive from both performance and cost perspectives. The use of polymers further increases the resistance to corrosion by sulfuric and carbonic acids often present in flue gases. An ongoing work explores different configurations of layered polyimide-copper macroscale hybrids for heat exchanger applications using numerical simulations. This paper explores a manufacturing pathway for producing such layered hybrid tubes that involves directly rolling and bonding tapes made of polymer and copper foil into tubes. A critical problem in the fabrication process is the bonding of metal and polymers. We explore approaches involving adhesives (epoxy, acrylic and silicone) for metal/polymer interfaces and direct welding (ultrasonic) for metal/metal interfaces that can be integrated into the manufacturing process. We report characterizations of the thermomechanical properties of these joining processes. This work paves the way for realizing cost-effective manufacturing of heat exchangers for low grade waste heat recovery.
KW - Adhesives
KW - Copper
KW - Dissimilar materials
KW - Heat exchangers
KW - Joining techniques
KW - Polyimide
KW - Polymer
KW - Roll-to-roll process
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U2 - 10.1115/IMECE2019-10621
DO - 10.1115/IMECE2019-10621
M3 - Conference contribution
AN - SCOPUS:85078761698
T3 - ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)
BT - Advanced Manufacturing
PB - American Society of Mechanical Engineers (ASME)
T2 - ASME 2019 International Mechanical Engineering Congress and Exposition, IMECE 2019
Y2 - 11 November 2019 through 14 November 2019
ER -