Visualization of Two-phase Flow Maldistribution in Brazed Plate Heat Exchangers
Brazed plate heat exchangers (BPHEs) are widely used in refrigeration and HVAC applications, but are susceptible to two-phase flow maldistribution especially when operated as evaporators. Existing visualization approaches are either limited to idealized conditions or suffer from poor optical transparency. This paper presents a novel visualization method in which one edge of a BPHE, parallel to the refrigerant inlet or outlet port, is removed by wire electrical discharge machining and replaced with a flat, transparent plate. The planar geometry allows the use of optically and infrared (IR)-transparent materials, enabling both high-speed videography and IR thermography of the two-phase flow at the channel entrances and exits. Preliminary tests with R134a and R1234ze(Z) at saturation temperatures between 5 °C and 15 °C demonstrate that distinct two-phase flow patterns in the inlet header can be clearly identified and differentiated under realistic operating conditions. Potentials of optical flow analysis of high-speed videos are shown to provide objective, quantitative indicators for flow regime characterization and comparison. IR imaging of the outlet port reveals non-uniform temperature distributions at the channel exits, providing independent evidence of maldistribution across the channel stack. Limitations of IR temperature accuracy due to the spectral properties of the sapphire window are discussed, and directions for improvement are identified.