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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,171 records · Page 65
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Electrodeposition of Fe–Ni alloy on Au(111) substrate: Metastable BCC growth via hydrogen evolution and interactions

The electrodeposition of Fe–Ni alloy is usually complicated by the effects of anomalous codeposition and hydrogen evolution. Although the influence of the deposition conditions on the alloy composition has been studied extensively, very few works considered the influence of growth conditions on the phase constitution. In this work, various electrodeposition conditions were investigated to grow Fe–Ni alloy films (<30 nm) with similar compositions in the Invar-to-equiatomic range on Au (111) substrate. Highly (110) oriented BCC phase Fe–Ni with a Ni fraction (ca. 40 at.% Ni) well beyond the equilibrium solubility limit (5 at.% Ni) was obtained with a significant alloy deposition partial current. An increase in the fraction of the BCC phase was found to be associated with a higher alloy deposition partial current, but not necessarily with an increase in the hydrogen evolution partial current. Motivated by the findings from this work, the formation of the metastable BCC phase is speculated to depend on the competing kinetics between the inclusion and desorption of hydrogen adatoms at the electrodeposited growth front.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Fabrication of porous transport electrodes: Development of quantitative approach for quality control

This work focuses on porous transport electrodes (PTEs), which integrate the anodic catalyst with the adjacent Ti porous transport layer (PTL). Challenges in catalyst deposition on PTLs, particularly at low loadings, motivated this study to evaluate various fabrication methods and characterization approaches. This work investigated Pt-treated PTLs coated with Ir-based catalysts using several common methods, including airbrush coating, rod coating, ultrasonic spray coating, electrodeposition, and sputter deposition, with catalyst loadings ranging from 2.9 to 0.1 mg/cm 2 , providing the opportunity for comparisons across a large set of samples produced by different methods. Two widely accessible characterization techniques: X-ray computed tomography (XCT) and scanning electron microscopy energy dispersive X-ray spectroscopy (SEM-EDS) were explored. Initial evaluation of selected samples with XCT provided qualitative insights into catalyst distribution, however comprehensive quantitative analysis was limited. SEM-EDS enabled detailed information on the catalyst distribution both qualitatively and quantitatively using two metrics. Atomic and surface area % ratios of Pt:Ir and Ti:Ir revealed trends in catalyst loading and losses into the PTL pores, as well as evaluating the homogeneity of catalyst coatings. The analysis demonstrated that ultrasonic spray coating, electrodeposition, and sputter coating produced the most homogeneous coatings, with minimal catalyst losses observed for electrodeposition and sputter coating. By adapting common techniques with novel, standardized methodologies, this work establishes a universally applicable framework for cross-study comparison of PTEs. The SEM-EDS approach provides a practical, accessible tool for PTE characterization and contributes a reference dataset supporting both research development and rapid quality control.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

The 3D printing and modeling of functionally graded Kelvin foams for controlling crushing performance

Mechanical impact protection is an important consideration in many applications, ranging from product transportation to sports. Cellular materials are typically used due to their desirable energy absorption properties and light weight. However, their large deformation and rate dependent responses (especially of polymer foams) are challenging to consider in design. Additionally, the use of foams with uniform properties, such as uniform density and uniform stiffness, often restricts the designed foams to only be suitable for a narrow range of mechanical impact conditions whereas real applications commonly face unpredictable situations. 3D printing offers fabrication flexibility and thus opens the door to create foams with tailored properties. In this work, we investigate the feasibility of using 3D printing for functionally graded foams (FGFs) that are optimal over a broad range of mechanical environments. The foams are fabricated by the recently developed grayscale digital light processing (g-DLP) method which can print parts with locally designed properties. These foams are tested under drop test conditions and with slower displacement control. We also model the large deformation behavior of FGFs using finite element analysis in which we account for the different viscoelastic behaviors of the distinct grayscale regions. We then use the model to examine the impact mitigation capabilities of FGFs in different loading scenarios. Finally, we show how FGFs can be used to satisfy real-world design goals using the case study of a motorcycle helmet. In contrast to prior work, we investigate continuous, functionally graded foams of a single density that differ in their viscoelastic responses. This work provides further insight into the benefits of viscoelastic properties and modulus graded foams and presents a manufacturing approach that can be used to produce the next generation of flexible lattice foams as mechanical absorbers.

3D printing↗
DOE OSTI2023

Developing and tuning a community scale energy model for a disadvantaged community

This work describes the development of a community-scale energy model for a mixed-use low-income community located in Huntington Beach, CA. An accurate community-scale energy model is useful for evaluating the use of limited capital resources used to invest in clean energy technologies. This work lays out the process of developing such a model while relying primarily on publicly available data and highlighting critical partnerships necessary for model development success. The primary contribution of this work is the demonstration of the process used to develop an accurate energy model for a disadvantaged community when minimal building and energy use data is available. The heart of the model is the physics-based community scale energy modeling platform URBANopt. Using a bottom-up load modeling approach, energy simulated energy use falls within 3% or less of aggregate annual utility data, and within 10% or less aggregate monthly utility data. The demonstrated model development and tuning process can be used by others to characterize other atypical communities, which may differ significantly from prototypical models.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Parameter identification methods for low-order gray box building energy models: A critical review

The body of knowledge on gray box building energy modeling (GBBEM) has been developed over the past few decades and has undergone some important changes recently. Starting with simple methods and simple buildings, the science of GBBEM has grown to encompass complex and more computationally intensive techniques and complex commercial buildings. Numerous works including a recent review have considered model structure and inputs in a nearly systematic way, but no extant work systematically reviews the approaches for GBBEM parameter search initialization and final identification, despite this being arguably the most difficult and impactful part of the modeling process. To this end, we critically review 55 extant works describing advantages, limitations, and domain of applicability of several classes of parameter initialization and optimization techniques specifically for GBBEM. We categorize the classes of methods and analyze the evidence of their applicability for different applications within the field of GBBEM. We find an emerging consensus that initialization of parameter searches for anything other than the simplest building elements is often challenging and sometimes requires a stochastic approach to begin the parameter identification process. After this initial process, faster methods have been used in some cases but often the nature of the problem requires stochastic methods for this portion of the process as well. For less complex systems, more deterministic and efficient methods have been shown to be effective. Finally, we draw conclusions as to the domain of applicability of different classes of initialization and optimization techniques for GBBEEM and offer suggestions for research directions that are likely to prove fruitful.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

QUIC-URB and QUIC-fire extension to complex terrain: Development of a terrain-following coordinate system

Ensemble-based approaches to prescribed fire planning cannot be supported by CFD-based models like FIRETEC and WFDS because they are too computationally expensive and cannot leverage LES approaches like CAWFE and WRF-SFIRE because too coarse of resolution. QUIC-Fire was developed to fill this gap but it cannot currently address complex terrain, typical for instance of the Western United States. In this paper, we describe the extension of the diagnostic wind model QUIC-URB, the wind engine of QUIC-Fire, to a terrain-following coordinate system. In particular, the paper presents the mathematical derivation of the wind solver leading to a linear system of equations that are solved through the successive over-relaxation method. The model is validated against a standard test used in previous works (the Askervein Hill) and against a new dataset from measurements in the Socorro Mountains, New Mexico. The terrain-following implementation captured the correct phenomenology for the isolated Askervein Hill, with a wind speed up at the top of the hill. We report the model agreed well with measurements on the upwind side of the peak, but overestimated speed-up on the downwind side of the hill. This is due to the inability of the model to generate flow separation and wake-eddy dynamics. On a common laptop, the divergence-free wind field was obtained in 6 s, making the solver appealing for coupled fire–atmosphere simulations. The Socorro Mountain was highly complex, with many cliff faces, peaks, and valleys. Although the model captures the magnitude and direction of inlet and outlet areas of the domain, it performs rather poorly in the valley region and in the regions near the steep cliffs. Hence, the model shows good agreement with data in areas of open sloped terrain but lacks in areas where flow separation and thermally driven effects may be present (neither effect was addressed in this work). Results highlight that future work should focus on the implementation of parameterizations of wake-eddies, similar to QUIC-URB’s building parameterizations, and on thermodynamic-driven flow.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

A systematic approach to resolve high impedance of multifunctional energy storage composites

Previous work has proposed and characterized the structural and electrical performance of Multifunctional Energy Storage Composite (MESC) structures: structural elements with embedded lithium-ion batteries which were developed by the Structures and Composite Laboratory (SACL) at Stanford University. This work conducts a comprehensive parametric study over the design variables in the manufacturing process to determine the root cause of increased DC impedance compared to commercial pouch cell batteries. Several MESC samples were assembled under various controlled environmental temperatures and pressures. The samples underwent Hybrid Peak Pulse Characterization (HPPC) to approximate the DC impedance as a function of state of charge (SOC). Failure limits of the battery with respect to assembly temperature and pressure were tested, and an MESC manufacturing simulation model was constructed in Abaqus to validate the manufacturing limits. Samples assembled without enough temperature or pressure failed due to a lack of structural integrity or hermetic seal. Conversely, samples which underwent elevated temperatures and pressures resulted in high DC impedance due to nonuniform electrolyte wetting. This work resolves the primary concern of MESC by achieving comparable DC impedance to commercial pouch cells of the same chemistry and testing procedure.

25 ENERGY STORAGE↗
DOE OSTI2020

Impacts of advanced diesel combustion operation and fuel formulation on soot nanostructure and reactivity

Advanced diesel combustion, accomplished via a single pulse fuel injection and high levels of exhaust gas recirculation (referred to as “PCCI”, partially-premixed charge compression ignition), is shown to be a path to reduce oxides of nitrogen and particulate matter simultaneously. This is well established in the literature. Less established is the extent to which such dilute combustion processes influence soot formation and affect soot that is emitted from diesel engines under such combustion modes. This work focuses on characterization of the nanostructure and oxidative reactivity of soot generated by a light-duty turbodiesel engine operating under a PCCI combustion mode, a dilute, low-temperature combustion process. Previous work on a type of PCCI combustion, referred to as high-efficiency clean combustion (HECC), showed soot samples having a fullerenic nanostructure, characterized by high levels of tortuosity of the fringe layers as seen in transmission electron micrograph images and as quantified using an image processing algorithm. Thermogravimetric analysis of the HECC mode soot samples showed that they displayed higher rates of oxidation than soot samples from a conventional diesel combustion mode. The present work returns to PCCI combustion, considering the timing of the main fuel injection, and the effects of operating on fuels rich in n-alkanes, particularly a fuel produced from a low temperature Fischer-Tropsch process (LTFT) and a renewable diesel fuel (RD) produced via hydrodeoxygenation of a plant oil. PCCI combustion conditions yield soot that shows higher reactivity compared to soot from the conventional combustion mode regardless of fuel type. LTFT and RD fuels produce soots with lower reactivity compared to ULSD. Soots produced from PCCI combustion have higher surface oxygen concentration and higher proportion of amorphous carbon. In addition, TEM images show that PCCI soots from all three fuels have smaller primary particle and particle aggregate sizes, and smaller graphene layers. These properties explain the higher reactivity of soot from PCCI combustion. The less reactive soots, which are produced from LTFT and RD fuel under conventional combustion, show internal burning during oxidation. However, soots with higher reactivity which are produced from late injection PCCI combustion and ULSD show shrinking core oxidation, most likely because of their overall amorphous structure.

42 ENGINEERING↗
DOE OSTI2020

ReaxFF-based molecular dynamics study of bio-derived polycyclic alkanes as potential alternative jet fuels

This work investigates the initial stages of the pyrolysis of HtH-1 (C 18 H 32 ; 2,2,7,7,8a,8b-hexamethyl-dodecahydrobiphenylene) and HtH-2 (C 18 H 34 ; 1,1',3,3,3',3'-hexamethyl-1,1'-bi(cyclohexane)), which are bio-derived polycyclic alkanes and potential jet fuels, using ReaxFF force field based molecular dynamics (MD) simulations. Global Arrhenius parameters, such as activation energies and pre-exponential factors, are calculated and used to analyze the overall decomposition kinetics of the fuels. HtH-1 decomposes faster than HtH-2 at the same temperature and density conditions, and they have a faster decomposition rate compared to some existing jet-fuels, such as JP-10. A systematic reaction analysis framework developed in this work is applied to determine a temperature-dependent decomposition mechanism. At lower temperature, the central C-C bond connecting the two cyclohexane rings is dominantly broken in both HtH-1 and HtH-2. However, C-CH 3 bond breaking becomes dominant with increasing temperature due to the large increase in entropy during this reaction. Major products from HtH-1 are C 5 H 8 and C 4 H 8 , and those from HtH-2 are C 4 H 8 and C 2 H 4 . The major products predict that HtH-1 has a higher sooting tendency than HtH-2, which is consistent with measurements. The impact of HtH-2 on the pyrolysis of HtH-1 is also investigated in their binary mixtures. HtH-1 and HtH-2 decompose by unimolecular reactions, and they rarely interact with each other during the pyrolysis of the mixtures. Furthermore, this work demonstrates that ReaxFF can be used to investigate pyrolysis and combustion chemistry of existing or future fuels and to contribute to the development of their chemical kinetic models without any a priori input and chemical intuition.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Optimization of energy requirements for CO 2 post-combustion capture process through advanced thermal integration

The energy optimization modeling work described here was performed to determine efficiency improvements that could be achieved for existing coal-fired power plants to retrofit a partial CO 2 capture from the post-combustion flue gas for carbon sequestration through thermal integration. The work presented includes optimization of the mono-ethanol amine (MEA)-based post-combustion CO 2 capture to reduce energy requirements that could be achieved at existing power plants by thermal integration of the steam turbine cycle, boiler, CO 2 compression train and post-combustion CO 2 capture process to offset efficiency and capacity losses that would be incurred by retrofit or implementation of post-combustion CO 2 capture. Furthermore, partial CO 2 capture, involving treatment of less than 100% of the flue gas leaving the plant and modular design of the CO 2 scrubbing system, was also investigated. Thermal integration of the steam turbine cycle with boiler and CO 2 compression train improved cycle and plant performance and offset, in part, the negative effects of post-combustion CO 2 capture. The best-analyzed integration options improved gross power output by 5% and net unit efficiency by 1.57%, relative to the conventional MEA process. Operating with 40% CO 2 capture increased gross power output by 11.6–14% (depending on the MEA thermal integration option), relative to the conventional MEA integration and 90% CO 2 capture. The improvement in net unit performance is larger compared to the improvement in turbine cycle performance because of the CO 2 compression work, which is also reduced by partial CO 2 capture.

42 ENGINEERING↗
DOE OSTI2026

The role of quantum computing in advancing scientific high-performance computing: A perspective from the ADAC institute

Quantum computing (QC) has gained significant attention over the past two decades due to its potential for speeding up classically demanding tasks. This transition from an academic focus to a thriving commercial sector is reflected in substantial global investments. While advancements in qubit counts and functionalities continue at a rapid pace, current quantum systems still lack the scalability for practical applications, facing challenges such as too high error rates and limited coherence times. Here, this perspective paper examines the relationship between QC and high-performance computing (HPC), highlighting their complementary roles in enhancing computational efficiency. It is widely acknowledged that even fully error-corrected QC will not be suited for all computational tasks. Rather, future compute infrastructures are anticipated to employ quantum acceleration within hybrid systems that integrate HPC and QC. While QC can enhance classical computing, traditional HPC remains essential for maximizing quantum acceleration. This integration is a priority for supercomputing centers and companies, sparking innovation to address the challenges of merging these technologies. The novelty of this work lies in its unique perspective, reflecting the collective insights of the Accelerated Data Analytics and Computing (ADAC) Institute, a global consortium of over 20 leading HPC centers. Recognizing the growing importance of QC, ADAC established a Quantum Computing Working Group in 2023 to foster collaboration and knowledge-sharing among its members. This paper synthesizes insights from the group’s collaborative efforts and incorporates findings from a member survey that captures shared experiences, ongoing projects, and strategic directions. By outlining the current landscape and challenges of QC integration into HPC ecosystems, this work offers HPC specialists practical and forward-looking guidance on the opportunities and implications of QC in computationally intensive endeavors.

Accelerated Data Analytics and↗
DOE OSTI2025

Nickel hydroxide–nickel carbonate competitive growth on carbonate surfaces

The thermodynamic and kinetic factors controlling the competitive heterogeneous nucleation and growth of ubiquitous metal carbonate and hydroxide phases are poorly understood. In this work, calcite (CaCO 3 ) and magnesite (MgCO 3 ) powders were reacted with NiCl 2 (0–600 μM) for 7 days at 22 °C and 5 °C. The reacted powders were analyzed with X-ray photoelectron spectroscopy (XPS), scanning electron microscopy, and energy-dispersive X-ray spectroscopy to characterize the Ni surface precipitates formed. Evidence from these techniques pointed to the formation of mixed Ni carbonate-Ni hydroxide amorphous surface precipitates. On calcite, XPS detected primarily Ni(OH) 2 despite the initial solutions being more supersaturated with respect to gaspéite (NiCO 3 ) than to theophrastite (Ni(OH) 2 ) by a factor of 17–18. In contrast, NiCO 3 was the dominant component detected by XPS on magnesite in the same conditions. Decreasing the temperature had the effect of increasing the proportion of NiCO 3 to the detriment of Ni(OH) 2 . The experimental observations were consistent with low lattice/cation size mismatch favoring NiCO 3 nucleation and temperature most influencing Ni(OH) 2 nucleation. Comparison to previous work on Co-reacted powders indicated the differences in lattice/cation size mismatch and/or water exchange rate impacted the composition of the surface precipitates more than the relative thermodynamic stabilities of the competing minerals. This work explored the heterogeneous growth regime of Ni carbonate and hydroxide phases on carbonate surfaces and shed light on the factors that control the competition between surface precipitates when mineral surfaces are in contact with aqueous solutions supersaturated with respect to multiple mineral phases. In conclusion, these results contribute to geochemists’ efforts toward interpreting data from geochemical systems with elevated Ni concentrations, improving Ni environmental remediation and recovery strategies, and predicting the fate and transport of Ni in geochemical systems.

Heterogeneous nucleation↗
DOE OSTI2023

Investigation of methane mass transfer and sorption in Marcellus shale under variable net-stress

Natural gas in shale exists as free and adsorbed gas, subject to prevailing pore pressures and stress conditions. Accordingly, to accurately estimate/predict the shale gas recovery potential, a central requirement is to represent gas transport and sorption behavior under varying stress conditions. The objective of this work is to facilitate the interpretation of laboratory-scale experiments, at relevant conditions, in an attempt to bridge the gap in scales between laboratory- and field-scale observations. We have conducted a series of high-pressure experiments on a full-diameter core sample from the Marcellus shale. These include gas loading (pressure-decay) and depletion (production) experiments with pure methane (CH 4 ) at variable stress conditions to characterize transport and sorption behavior under reservoir-relevant conditions. Here we have formulated and applied a novel integral model for mass transfer and storage in multi-porosity shale systems that allows us to effectively investigate transport and sorption phenomena: We delineate gas transport by interpreting helium (He) pressure-decay experiments and demonstrate how to use the information gained to calculate the relevant transport coefficients of CH 4 and other gases. A separate measurement of the CH 4 sorption isotherm on a smaller sample (a shale cube) was interpreted and combined with the transport description to predict the production behavior of CH 4 from the experiments with the full-diameter core. Our experiments demonstrate that the representation of sorption hysteresis is crucial for predicting and guiding shale gas production: At the end of both gas production experiments, approximately 20% of the initial gas in place remained in the core. Without accounting for sorption hysteresis, our modeling demonstrates that the CH 4 production could be overestimated by 10%. We demonstrate that our integral, triple-porosity model provides an effective approach for the interpretation and prediction of gas transport and sorption behavior during loading and production experiments on shale cores under variable net-stress conditions. In summary, our work combines measurements and modeling of mass transfer and sorption in shales at different scales to validate a characterization approach that facilitates an improved understanding of shale gas production. Furthermore, the triple-porosity model utilized in our work defines a potential pathway for the translation of laboratory-scale experimentation to larger-scale applications.

58 GEOSCIENCES↗
DOE OSTI2020

CFD-DEM and PR-DNS studies of low-temperature densely packed beds

Over the past few decades, granular media is gaining attention as a viable option for heat transfer fluids (HTFs). Several research efforts are studying the use of particle-based heat transfer fluids in a wide variety of applications. With this motivation, the current work focusses on analyzing the different heat transfer mechanisms in low-temperature mono-sized densely packed granular media. To study the heat transfer behavior of granular media at different scales, the current work employs a two-way coupled computational strategy. The motion of particles is solved using the Discrete Element Method (DEM) and the interstitial air is solved using a Finite-Volume (CFD) approach. The Open-Source library CFDEM Coupling® is used in the current study to join the Finite Volume PISO solver of OpenFOAM® and the DEM solver of LIGGGHTS®. Typically, particle-particle contact conduction and particle-air convection are the most popular closure models. But recent research identified a different heat transfer phenomenon in packed beds that cannot be identified by conduction or convection models. While closure models were developed to implement this on a CFD-DEM framework, they did not capture the effect of intra-particulate thermal gradients on this phenomenon. Hence the current work also employs Particle-Resolved Direct Numerical Simulations (PR-DNS) to gain valuable insights allowing for the modification of existing models. A new closure model is then proposed here and is implemented in the CFD-DEM framework. This model provides key insights into the different heat transfer mechanism of packed beds.

42 ENGINEERING↗
DOE OSTI2022

Experimental measurements and mathematical modeling of cold plate for aviation thermal management

Herein, this study, which has been motivated by the recent applications of the cold plate device in aviation thermal management, reports on physics-based mathematical models derived from the conservation laws of mass, momentum, and energy, and empiricism-based models. One of the objectives of the present work is to report on an elaborate and successful experimental work carried out on an additively manufactured device for the purpose of rigorously validating the numerical predictions. The excellent agreement between the numerical predictions and measured performance provides much needed confidence in the implementation, in the software package, of the offset-strip fin passage correlations, as well as in the software implementation of user-defined wavy fin correlations for aerospace heat exchangers and cold plates operating with ram air at Reynolds numbers below 8000. The contributions of this work can also be found in the development of a new and accurate thermal-hydraulic analysis procedure, referred to in this paper as plate-fin analogy. Results from this procedure are compared with those from thermal resistance network. The comparative study in this paper of the bulk and discrete enthalpy flux method is also new, as is the relative assessment of four off-set strip fin thermal-hydraulic models.

42 ENGINEERING↗
DOE OSTI2025

Additional considerations in analytical solution for time-dependent heat conduction in a three-dimensional multilayer sphere

This work presents an analytical method to solve the heat conduction equation in three dimensions for problems consisting of multilayer concentric spheres. The method can be used to treat time-varying heat conduction problems where the heat source that drives the transient is time-invariant. Equally applicable to all Poisson-type problems with concentric spherical geometry, the method consists of representing the solution as a summation of weighted eigenfunctions. The weights for each eigenfunction are computed algebraically. Previous work has already established the core constituents of the methodology. The current work augments the existing methods by including consideration of nonzero interface resistance between layers and explicit discussion on the boundary condition homogenization required to treat inhomogeneous problems. Also, two demonstration problems are presented. One demonstration problem is based on the method of manufactured solutions and therefore allows for comparison with exact expressions for the solution temperature distribution. The second, more complex, demonstration problem relies on the finite element method for comparisons. The expected convergence behavior is observed for both demonstration problems.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Ultra-low thermal resistance and pressure drop copper and copper-tungsten diamond-shaped pin fin cold plates for liquid cooling of electronics

Modern and future data centers face increasing cooling challenges due to increasing chip thermal design power and die size, along with the need to reduce energy consumption used for cooling. High performance cooling solutions that maintain a low chip junction temperature are needed to ensure electronics reliability. This work develops an ultra-low thermal resistance and low pressure drop 75 mm × 75 mm cold plate, intended for next-generation electronics cooling. The cold plate features an array of diamond-shaped pin fins and integrated copper tungsten heat spreader, selected for its low coefficient of thermal expansion which reduces thermomechanical deformation and allows for closer integration of the cold plate with silicon dies. Starting with 300 candidate designs, three-dimensional computational fluid dynamics simulations predict the thermal-hydraulic performance of cold plate subsections. The highest performing geometries are evaluated with high fidelity simulations. Four cold plates are manufactured for experiments: three with diamond-shaped pin fins and one with straights fins for comparison purposes. The cold plates are fabricated from copper-tungsten (CuW), copper (Cu), or aluminum-silicon-magnesium alloy (AlSi10Mg). The diamond-shaped pin fins achieve a roughly 15 % lower thermal resistance compared to the conventional straight fin microchannel. The highest performing design achieves a chip-to-coolant (including thermal interface material) thermal resistance of 9.0 K/kW in CuW and 6.9 K/kW in Cu under a 1 kW heat load with an inlet-to-outlet pressure drop of 9.0 kPa and water as the working fluid. This work demonstrates ultra-low thermal resistance and pressure drop cold plates for large die, high heat load applications, and shows that CuW is an attractive cold plate material for improved reliability in next generation data center cooling.

Coefficient of thermal expansion↗