Development of Magnetohydrodynamic Avionics Cooling Using Complex Structures Realized Through Additive Manufacturing

Abstract

As electronics get smaller and faster, novel thermal management systems are needed that are capable of dissipating higher heat fluxes. Additive manufacturing and advanced materials, such as liquid metals and synthetic ceramic, offer new opportunities to realize thermal systems. This paper investigates the use of additive manufacturing to develop thermal structures designed around liquid metals to provide active magnetohydrodynamic cooling by obviating the need for moving parts and addressing the corrosive issue of liquid metal. Optimized components for the magnetohydrodynamic cooling prototype have been conceptualized, modeled, simulated, and fabricated to enhance flow and thermal transport efficiency, magnetic flux intensity, material compatibility, and manufacturing feasibility. Prototype systems were used to determine electrical and magnetic saturation thresholds of electrodes and electromagnets under direct current and alternating current. Additionally, the effect of electroplated Hartmann wall on flow rate and pressure drop was determined. The magnetohydrodynamic cooling prototype was shown to reach volumetric flow rates of up to and generated pressure due to Lorentz forces of up to 230 Pa, resulting in heat transfer improvement relative to passive prototype of 1.054. Magnetohydrodynamic cooling was also compared with alternative liquid metal cooling techniques to prove its benefits.