International Journal of Heat and Mass Transfer
International Journal of Heat and Mass Transfer
a r t i c l e i n f o a b s t r a c t
Article history: A series of experiments was performed to investigate the enhancement effect of micro fin, contact pres-
Received 18 September 2018 sure, and interface temperature on thermal contact conductance. The specimens were made of 7075 alu-
Received in revised form 3 December 2018 minum alloy. The contact surfaces of specimens with micro fin were specially machined such that two
Accepted 13 January 2019
specimens were coaxially inlayed together. Contact pressure ranged from 2 MPa to 4.2 MPa, and interface
temperature ranged from 165 °C to 180 °C and 215 °C to 227 °C. Experimental results showed that the
micro fin could enhance thermal contact conductance, and the contact heat transfer enhancement effects
Keywords:
caused by the micro fin gradually increased with contact pressure. Thermal contact conductance was
Thermal contact conductance
Micro fin
high under higher interface temperature. The loading process changed the enhancing effect of the micro
Contact pressure fin, and enhancement of contact heat transfer was greater in the unloading process than in the loading
Interface temperature process. A qualitative analysis on the enhancement effect was conducted to explain the contact heat
transfer enhancement effect for different micro-finned surfaces.
Ó 2019 Published by Elsevier Ltd.
1. Introduction Verma and Mazumder [5] quantified the effect of asperity size
and shape on thermal contact conductance by using a numerical
Thermal contact conductance is commonly encountered in method. The results revealed that thermal contact conductance
engineering applications, such as casting, electronics, heat treat- was a strong function of asperity size and a weak function of asper-
ment, and spacecraft. The steady-state heat transfer method is a ity shape. Numerical results by Fang et al. [6] reveal that thermal
conventional and common technique of measuring thermal con- contact conductance increases as the decrease of surface rough-
tact conductance [1]. However, the physical mechanism of contact ness. Cui et al. [7] and Zhang et al. [8] concluded that the effect
heat transfer is extremely complex because it is nonlinearly of improving contact heat transfer by pursuit of high surface finish
affected by contact pressure, interface temperature, interface and loading pressure was limited. Gou et al. [9] proposed a numer-
roughness, and surface geometry. Thermal contact conductance is ical model to predict the thermal contact conductance of rough
enhanced by high contact pressure, flat surfaces with low rough- surfaces, the model provides a method to investigate the effect of
ness and thermal interface materials, such as thermal grease. surface asperities on thermal contact conductance.
Thermal contact conductance has been intensively researched. Hysteresis effect, in which the thermal contact conductance in
Yovanovich [2] reviewed thermal contact resistance in microelec- the unloading process is higher than that in the loading process,
tronics extensively. Tang and Zhang [3] investigated the effect of has been observed in many works [10–12]. Joseph et al. [13] inves-
contact pressure on thermal contact conductance under high tem- tigated the effect of thermal and load cycles on thermal contact
perature experimentally. The results showed that thermal contact conductance at cryogenic temperatures. They summarized that
conductance was nearly directly proportional to interface pressure, the thermal and load cyclings increased thermal contact conduc-
which was inconsistent with most reported exponential relations. tance continuously. This result was consistent with that of Li
Dou et al. [4] found that thermal contact conductance had an expo- et al. [14] but slightly different from the conditions at high temper-
nential relationship with temperature and contact pressure. ature. Wahid and Madhusudana [15] examined the effects of over-
loading and load cycling on thermal contact conductance. Their
results showed that the enhancement of contact heat transfer by
⇑ Corresponding author at: School of Energy and Environmental Engineering, cyclic loading was rather small, but the overloading effect on the
University of Science and Technology Beijing, Beijing 100083, China. enhancement of thermal contact conductance was remarkable.
E-mail address: [email protected] (R. Dou).
https://doi.org/10.1016/j.ijheatmasstransfer.2019.01.058
0017-9310/Ó 2019 Published by Elsevier Ltd.
R. Dou et al. / International Journal of Heat and Mass Transfer 134 (2019) 482–488 483
Gopal and Whiting et al. [16] focused on the effect of load cycling
on thermal contact conductance and discovered that load cycling
for a variety of surface topographies and maximum contact pres-
sures had minimal effect on thermal contact conductance, but an
exception was provided for the first load cycle.
Many different kinds of thermal interface materials are created
to enhance the heat transfer between solid surfaces, but there is a
clear need for dry contact thermal interface solutions at low pres-
sure [17]. And at some high temperature conditions, the applica-
tions of thermal interface materials are not applicable.
Here, the enhancement effect of micro fin on contact conduc-
tance was discussed. Four pairs of specimens were prepared, and
a qualitative analysis of the enhancement effect was performed
to explain the contact heat transfer enhancement effect of different
micro-finned surfaces. The present paper proves that: the flat and
smooth contact surface is not the only way to enhance contact heat
transfer, a micro structured surface could also enhance contact
heat transfer.
2. Experimental method
Table 1
. Thermal conductivity of 7075 aluminum alloy [18].
tribution along the axis of the hot-side (a) and cold-side specimens
(b).
(a) Sp. 2
T ¼ kx þ c ð1Þ
where k is the gradient of temperature, °C m1; x is position, m; and
c is intercept.
Heat flux qa (heat flux along the axis of hot side specimen) and
qb (heat flux along the axis of cold side specimen) are obtained
according to Fourier’s law (Eq. (2)).
q ¼ kdT=dx ¼ kk ð2Þ
1 1
where k is the thermal conductivity of the specimen, W m °C .
Under ideal conditions, qa and qb should be equal, but a small
difference is observed between these two fluxes because heat leaks
in the radial direction. For all experiments, the maximum relative
difference between qa and qb. is 8.9%. Here, we take the arithmetic
mean values of qa and qb as the heat flux through the contact inter-
face [19].
qavg ¼ ðqa þ qb Þ=2 ð3Þ
(b) Sp. 3
where qavg is the arithmetic mean value of the heat flux in speci-
mens (a) and (b), W m2 °C1.
The surface temperatures Ta and Tb of Specimens (a) and (b) can
be obtained by using the extrapolation method according to the
linear temperature distribution function of Specimens (a) and (b),
respectively.
qa d
Ta ¼ T4 0:006 þ ð4Þ
ka 2
qb d
Tb ¼ T5 þ 0:006 þ ð5Þ
kb 2
where ka and kb are thermal conductivity of Specimens (a) and (b),
respectively, W m1 °C1. The positions of temperatures T4 and T5
are shown in Fig. 2.
The interface temperature difference is DTint.
DT int ¼ T a T b ð6Þ
(c) Sp. 4
Thus, the thermal contact conductance hc can be obtained by Eq.
(7). Fig. 4. Contact status of specimens with same surface geometry.
R. Dou et al. / International Journal of Heat and Mass Transfer 134 (2019) 482–488 485
4. Uncertainty analysis
The loading curves of Sp. 4 and Sp. 1 in Fig. 6(b) show that when
the contact pressure is not higher than a certain critical contact
pressure (In this study, the critical contact pressure is approxi-
mately 2.68 MPa.), the addition of micro fin can weaken the con-
tact heat transfer. However, this condition reverses at high
contact pressure.
Fig. 6(a) and (b) show that during the unloading process, all the
thermal contact conductances of Sp. 2, Sp. 3, and Sp. 4 are greater
than that of Sp. 1. The unloading curves in Fig. 6(b) show that: at
the contact pressure of 2.39 MPa, the thermal contact conductance
is enhanced to 1.95 times that of Sp. 1 by Sp. 2; At the contact pres-
sure of 4.17 MPa, thermal contact conductance is enhanced by 1.76
times that of Sp. 1 by Sp. 2. A comparison between the loading and
unloading processes shows that the enhancing effect of the micro
fin on contact heat transfer is greater in the unloading process than
in the loading process.
In addition to contact pressure and loading process, the inter-
(a) Loading process face temperature is a parameter that affects contact heat transfer
greatly. Fig. 7(a) shows that the thermal contact conductances of
Sp. 1 and Sp. 3 are high at an interface temperature of 215–
224 °C. The reason is that the increase in interface temperature
decreases the hardness of the solid material and increases the real
contact area. However, the relation between for Sp. 2 and Sp. 4 is
slightly complex, in Fig. 7(a) the two curves at different interface
temperatures intersect. Thermal contact conductance is low under
high interface temperature when the contact pressure is below the
crossed point. This abnormal phenomenon shows the complicated
aspect of the contact heat transfer, and the addition of the micro fin
makes the mechanisms increasingly complex.
High interface temperature during the unloading process indi-
cates high thermal contact conductance for all the specimens
(Fig. 7(b)). Moreover, all the curves are approximately parallel with
each other. The data in Fig. 7(b) show that: at unloading process,
the increase in interface temperature increases thermal contact
conductance. The curves also show that at different interface tem-
(b) Unloading process peratures, the micro fin can greatly enhance the contact heat
transfer.
Fig. 7. Effects of interface temperature on thermal contact conductance. Many works prove that the higher the surface roughness the
lower the thermal contact conductance [4,7,8,19,20]. This is
because the surface roughness decreases the real contact area at
heat transfer, and the size and geometry of the micro fin have
same contact pressure and temperature. But the micro fin could
remarkable effects on thermal contact conductance. The error bars
extend the surface area, and because the micro fin could inlayed
in Fig. 6(a) demonstrate that the enhancements are not affected by
together, so it increases the contact area, finally enhances the ther-
experimental uncertainty.
mal contact conductance.
The surfaces of Sp. 2 and Sp. 3 have triangular micro fins, and
the fin size of Sp. 2 is larger than that of Sp. 3 (Fig. 3). Fig. 3 shows
5.2. Heat transfer enhancement analysis
that the fin tip angle h of Sp. 2 is approximately 21°, whereas that
of Sp. 3 is approximately 13°, which is smaller than that of Sp. 2.
The force analysis of one single micro fin is as follows. Fig. 8
The micro fin on Sp. 4 is similar to a rectangular fin, and its angle
shows the force analysis for Sp. 2 and Sp. 3, which have the same
is not greater than 6°. These geometry characteristics result in dif-
form of fin geometry. The width of the fin base is W, fin height is
ferent contact heat transfer enhancement effects. Furthermore,
H, and the fin tip angle is h (Fig. 3). The geometrical relationship
Fig. 6(a) shows that the thermal contact conductance of Sp. 2 is
suggests that L = 0.5 W/sinh. The forces on the fin include down-
the largest at the different contact pressures, and Sp. 1 has the low-
ward pressure force Fp, supporting force F0p at the fin tip, friction
est value during the unloading process.
forces FfL and FfR on the side surfaces (Ff = FfL = FfR), normal forces
Fig. 6(b) shows that during the loading process under the tem-
FnL, and FnR on the side surfaces (Fn = FnL = FnR). The force balance
perature range of 215–227 °C, the thermal contact conductance of
in the vertical direction provides the result shown in Eq. (12).
Sp. 2 is greater than that of Sp. 3, and both are greater than that of
Sp. 1, indicating that the micro fin can enhance contact heat trans- 2ðF f cosh þ F n sinhÞ ¼ F p F 0p ; ð12Þ
fer. At the contact pressure of 4.17 MPa, the thermal contact con-
ductance of Sp. 2 is 79% greater than that of Sp. 1. However, at where Ff = fFn, and f is the static friction coefficient among the alu-
the low contact pressure of 2.40 MPa, the thermal contact conduc- minum alloys. Then,
tance of Sp. 2 is only 1.20 times that of Sp. 1. Comparison between 1 F p F 0p
Sp. 3 and Sp. 1 and between Sp. 2 and Sp. 1 show the same trend, Fn ¼ : ð13Þ
2 f cos h þ sin h
that is, as the contact pressure increases, the contact heat transfer
enhancement effects caused by the micro fin gradually increase. The normal pressure rn on the side surface is
R. Dou et al. / International Journal of Heat and Mass Transfer 134 (2019) 482–488 487
The micro fins on Sp. 4 increase the surface area to 4.0 times References
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Appendix A. Supplementary material