Pores Per Inch Research Articles

Pressure Drop in a Metal Foam Centrifugal Breather: A Simulation Approach

One of the main issues faced in the operation of a metal foam centrifugal breather is the high pressure drop. This study investigates the pressure drop of a metal foam centrifugal breather. The numerical simulation research method is adopted. The DPM model is used to calculate the two-phase flow field of the metal foam breather, and the porous medium model is used to replace the metal foam at the breather. The resistance caused by the metal foam is replaced by a distributed resistance added to the fluid. The effects of flow rate, rotational speed, porosity, PPI (pores per inch), and temperature on the pressure drop of the breather are analyzed. The results indicate that rotational speed, flow rate, porosity, and PPI significantly influence the resistance of the metal foam centrifugal breather. The resistance of the breather is directly proportional to the rotational speed, flow rate, temperature, and metal foam pore density, and inversely proportional to the porosity. Temperature has a minor impact on the resistance of the metal foam centrifugal breather. Therefore, the metal foam centrifugal breather is more suitable for low-speed operating conditions.

Understanding the impact of nickel coating on the mechanical and corrosion behaviour of copper foams

ABSTRACT This study used a sponge replication technique to fabricate open-cell copper (Cu) foams with varying pore sizes. Nickel coating was applied via electrolysis to produce nickel-copper (NiCu) foams to enhance the Cu foams' energy absorption efficiency and corrosion resistance. The foams were characterized under static conditions to assess their compressive and corrosion properties. The nickel coating improved compressive strength by increasing foam strut thickness and reducing defects, as observed via scanning electron microscopy (SEM). The 10 Pores per inch (PPI) NiCu foam shows a substantial increase in compressive strength, close to 17.7%, compared to the 10 PPI Cu foam, resulting in a maximum compressive strength of 11.3 MPa. Similarly, 20PPI NiCu foam shows an increase of compressive strength of 20% when compared to 20 PPI Cu foam. NiCu foams significantly reduced corrosion current density compared to uncoated Cu foams, indicating enhanced corrosion protection from the nickel coating.

Synergistic effect of alcohol polyoxyethylene ether sodium sulphate and copper foam on methane hydrate formation

AbstractNatural gas is the cleanest fossil energy source and its consumption is increasing rapidly, so an efficient natural gas way of storing and transporting is urgently needed. Solidified natural gas (SNG) technology is gaining traction because of its higher safety, lower cost, and flexible storage and transportation modes. To improve the methane uptake rate in SNG technology, this work investigated the growth of methane hydrate in fatty alcohol polyoxyethylene ether sodium sulphate (AES) solution with the addition of three different pores per inch (PPI) of copper foam (CF). The results showed that the addition of AES caused the hydrate to grow upwards along the wall, and the methane uptake in the 300 ppm AES solution was increased by 623% compared to pure water. CF not only provided more nucleation sites for hydrate but also transferred the heat generated during hydration. Moreover, there was a synergistic effect between AES and CF and the solution could continuously transport upward along the continuous metal skeleton to increase the gas–liquid contact area. Thus, the formation rate and induction time of methane hydrate improve. Hydrate had the highest methane uptake in the 20 PPI CF system and the lower the pressure, the greater the ability of CF to promote hydrate formation. The methane uptake improved by 27.6% and the induction time was reduced by 59.7% compared to the pure AES system at 6 MPa. This work is aimed at advancing SNG technology (especially at low pressure) and informs the theoretical foundation.

Microstructural influence on compressive behavior and strain rate sensitivity of open-cell nickel foam

Open-cell nickel foam (OCNF) is a highly porous, three-dimensional material with potential applications in various fields, such as energy storage, catalysis, and thermal management. However, the microstructural effect of pores per inch (PPI), cell size and strain rate (SR) sensitivity on the mechanical properties of OCNF has not been fully explored. We characterized the samples of OCNFs using digital image correlation (DIC), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS) mapping. Our results show that the OCNF exhibits a linear elastic response under quasi-static compression, with high compressive strength and a low compressive modulus. The dynamic compression test results demonstrate that the OCNF has a high energy absorption capacity and good structural stability. We designed and constructed a method to generate the 3D meshes based on the scans of the OCNFs obtained by X-ray micro-CT. The 3D meshes allow the finite element method to capture the key features of the mechanical behaviors with high fidelity. The simulated mechanical behavior of the OCNFs demonstrates strong concordance with the observed experimental findings.

Thermal analysis of metal foam and nanofluid integration in an asymmetrical heated channel

The flow and heat transport presentation of the nanofluid flowing through the metal foam (MF) positioned inside the asymmetrical heated horizontal channel is evaluated computationally in the current study. The MF of 20 pores per inch (PPI) with porosity 0.918 is inserted into horizontal channel test section. The test segment is heated from the top wall with the help of plate (aluminum) heater assemblage positioned at the top of the channel. The novelty of the current examination is to extract the consequences of nanofluids such as Al2O3-H2O and CuO-H2O flowing through the MF filled test segment at various velocities ranging from 0.02 to 0.15 m/s. The conjugate heat transport examination is executed through MF region using integrated DEF (Darcy Extended Forchheimer) with LTE (local thermal equilibrium models). The improvement in thermal presentation achieved for nanofluids are likened with H2O and H2O-C2H6O2 (water with 50 % ethylene glycol) solution and also with clear channel. The procedure adopted in the current analysis is initially confirmed with the help of comparison of present work result with literature upshots. The outcomes are presented in terms of friction factor (FF), Nusselt number (Nu), Colburn j factor, performance evaluation criteria (PEC) and pumping power (PP). The CuO-H2O nanofluid showed the best performance (average PEC of 1.4) among all the fluids considered in the present examination.

Performance optimization of triple tube heat exchanger using aluminum metal foam: A comprehensive numerical investigation

Metal foam is a porous medium with high porosity, convoluted flow pathways, strength-to-weight ratio, and thermal conductivity employed in heat exchanges and other engineering applications because of its properties. Therefore, a novel circular tube filled with aluminum metallic foam is proposed to improve hydraulic thermal performance and reduce pumping power losses and metal foam volume. The current work considers the Brinkman-Forchheimer Extended Darcy model for forced convection flow and the local thermal equilibrium (LTE) model for heat transfer under a constant thermal boundary condition. The governing equations are solved using the finite volume method (FVM). The variable parameters are the pore per inch (PPI) of 10–50, the porosity εrange of 0.79–0.95, and the Reynolds number range of 2500–7000. The results show that the performance index (PI) has its maximum value of 6.8 at 10PPI and ε =0.95 in the heat exchanger; this enhancement at 10PPI is 13% and 34.48% more as compared to the PI value at ε =0.85 and ε =0.79 and at a fixed inner annulus Re of 7000. The average Nusselt number (Nu) increased by 81.63%, 104.3%, and 120% compared to the foamless tube at 10, 20, and 30PPI andε =0.95, respectively, in an intermediate tube. Heat transfer coefficients (HTC) considerably increase compared to foamless tubes nearly 3.2 times, 3.8 times, and 4.2 times at 10, 20, and 30PPI, respectively, at 2500 Re and 144%, 175% and 200% more at 7000 Re. The maximum reduction ratio in normalized friction factor ratio (fP/fNoP) at 10PPI is approximately 50% compared to (fP/fNoP) at 30PPI and 25% at 20PPI; it occurs at 7000 Re. The normalized area goodness factor ratio has the maximum value at 10PPI and ε =0.95, which is 5.8, and for 20 and 30PPI, it is 3.5 and 2.3, respectively. This shows that aluminum metal foam in triple tube heat exchanger's intermediate tube at 10PPI and porosity of 0.95 can be the optimized results for performance enhancement.

Thermal Properties of Disodium Hydrogen Phosphate Dodecahydrate–Coated Metal Foam/Sodium Acetate Trihydrate Composite as Phase Change Material

Abstract Salt hydrates, like the sodium acetate trihydrate (SAT), possess a remarkable ability to store copious amounts of thermal energy, thanks to their ingenious utilization of a high latent heat of fusion. This unique property makes them a compelling choice for various energy storage applications. In this study, aluminum and copper foams with pore sizes of 40, 80, and 110 pores per inch (PPI) coated with disodium hydrogen phosphate dodecahydrate were prepared, and their effects on the SAT solidification temperature, latent heat of fusion, and thermal conductivity were investigated. The samples' thermal conductivity was measured using the guarded heat flow method. Thermal properties, including latent heat of fusion and supercooling were measured using the T-History method. The results showed that the metal foam matrix is an effective method of enhancing the thermal conductivity of SAT while occupying a small volume of the composite. The copper foam with a PPI of 80 was able to increase the effective thermal conductivity to 2.62 W/(m⋅K), an increase of 388.15% compared to pure SAT while occupying approximately 6.5% of the composite volume. The T-History results showed a solidification temperature of 57.52 °C along with a super cooling of 3.28 °C for the same sample set. Furthermore, it was also found that copper samples significantly outperformed the aluminum ones, despite the higher porosity.

Three-dimensional simulation of a proton exchange membrane fuel cell with non-integrated metal foam as flow distributor

In proton exchange membrane fuel cells (PEMFCs), the presence of metal foam in the flow channels improves the polarity diagram and increases the cell generated power, but this leads to an increase in pressure drop and, as a result, an increase in parasitic power. In this study, two types of non-integrated arrangements of metal foam are introduced, which, in addition to having high generated power, have lower pressure drop, and subsequently, lower parasitic power, and will also result in a more uniform distribution of temperature and current density. In the first arrangement, which is called IPTG, an abbreviation of Increased Porosity Toward the gas diffusion layer (GDL), the channels are divided into four equal parts with variable porosities from 0.65 to 0.95, in such a way that the metal foam layer with the highest porosity (0.95) is located in the closest area to the GDL. In the second arrangement which is called Reduced Porosity Toward the GDL, the metal foam layer with the least porosity (0.65) is located in the closest area to the GDL. To make a better comparison between the present model and the conventional one, the net power parameter with subtracting parasitic power from generated electrical power of the fuel cell is calculated for all models. The numerical study of this paper is conducted by developing a three-dimensional computational fluid dynamics model by employing user-defined functions. The results show that the net power of the PEMFC with IPTG arrangement is 3.8 % higher than that of the one with integrated metal foam arrangement with a porosity of 0.95. Also, the higher the pores per inch (PPI) of metal foam used in the non-integrated metal foam model, the greater the net power of the fuel cell, so that, the net power of PEMFC with IPTG arrangement with PPI=80 is 3.2 % more than that of PPI=20.

Study on the flow and heat transfer characteristics inside high-porosity open-cell copper foams: Experimental and numerical explorations

A metal foam with an open-cell structure is a type of material with low flow resistance, high specific surface area, and strong fluid mixing ability. Open-cell metal foams have broad application prospects in electronic component cooling, multiphase heat exchangers, and compact heat exchangers for aerospace applications. This paper presented experimental and numerical analyses of the flow and heat transfer characteristics of five different copper foams under forced air convection. The pores per inch (PPI) of selected foams were 10, 20, 30, 40, and 60, with porosities ranging from 0.968 to 0.973. Analysis of the collected heat transfer and pressure drop data yielded the overall heat transfer coefficient, unit pressure drop, normalized average wall temperature, inertia coefficient, and resistance coefficient. The influence mechanisms of the porosity and flow velocity on heat transfer were analyzed and discussed. The numerical simulation and experiment fitted well. The results showed that increasing porosity led to a significant increase in heat transfer coefficient and unit pressure drop. The 60 PPI foam brought the maximum pressure drop while achieved the minimum thermal resistance.

Brazing of Porous Nickel to Copper and Stainless Steel: Microstructure and Mechanical Properties

A porous nickel (Ni) was brazed to copper (Cu) and stainless steel 304 (SS304) using VZ2250 and MBF67 brazing filler metal with a composition of 77.4Cu-9.3Sn-7.0Ni-6.3P and 64.5Ni-25Cr-6P-1.5Si (Cu: Copper, Sn: Tin, Ni: Nickel, P: Phosphorus, Cr: Chromium, Si: Silicon), respectively for joint microstructure and mechanical properties analysis. Porous Ni with a pore density of 15 pores per inch (PPI) was sandwiched between Cu/VZ2250 and MBF67/SS304. A brazed joint of Cu/Porous Ni/SS304 with VZ2250 and MBF67 brazing filler metal was prepared in a high vacuum furnace at different brazing times of 5, 10, and 15 minutes for 1015 °C with a heating and cooling rate of 10 °C/min, respectively for comparison purpose. The microstructure and mechanical properties of the brazed joint were investigated to identify the joint ability after the brazing process. Scanning Electron Microscope (SEM) equipped with Energy Dispersive X-Ray Spectroscopy (EDS) confirmed the interfacial microstructure by the formation of the diffusion filler metal (dark grey colour) for the Cu/Porous Ni/SS304 with VZ2250 and MBF67 brazing filler metal. For shear strength tests, the value decreases with an increase in the brazing time. The shear strength tests for the brazed joint of Cu/Porous Ni/SS304 with VZ2250 and MBF67 brazing filler metal show the maximum shear strength test value can be achieved for the brazing time of 5 minutes. The decreasing shear strength value was observed with differences in structural data of porous Ni due to the softening after the brazing process. Keywords: Brazing, Microstructure, Porous Nickel, Shear Strength.

Brazing of Copper Foam Using Cu-4.0Sn-9.9Ni-7.8P Filler Foil: Effect of Brazing Temperature and Copper Foam Pore Density

Copper (Cu) foam is a promising material that owns a high surface area that can be utilized in a thermal application. In this research, the brazing of Cu substrate to Cu foam in the sandwich configuration using Cu alloy filler foil was carried out. The foam at different pore per inch (PPI) of 15, 25 and 50 are brazed at different brazing temperatures. Mechanical and microstructure analysis were conducted to investigate a suitable brazing temperature and the best pore density of foam. The compressive strength of brazed 50 PPI foam has yielded the highest due to the highly dense interconnected branches. While the highest shear strength of brazed interface using 15 PPI foam has been recorded. The large branch size of 15 PPI foam has contributed to the sound joint between the brazed joint interface of Cu substrate and foam. Both mechanicals analysis above exhibits a highest strength at 660 °C as a brazing temperature The shear stress-strain curve of Cu substrate and foam brazed joint interface shows a brittle behaviour which accordance with the discoverable brittle phases of Cu3P and Ni3P using X-ray diffraction (XRD). Scanning electron microscopy (SEM) and Energy dispersive X-ray spectroscopy (EDX) have presented the formation of Cu3P and Ni3P at the brazed joint interface of Cu substrate and foam.

Experimental study on Finding stable catalytic methane decomposition for hydrogen production

This study attempts to find active and stable catalysts for H2 production from catalytic methane decomposition (CMD). Experimental results show that metal-based (Ni, Fe, and Ni–Fe alloy) and carbon-based (biochar and activated carbon) catalysts are gradually deactivated due to carbon deposition during the CMD reaction. Although the CMD performance can be enhanced using bimetallic catalysts supported by either metal oxide (Al2O3) or activated carbon, deactivation due to carbon deposition is still inevitable. It was also found the carbon-based carbon catalyst has lower activity as compared with the metal-based catalysts. When using commercially available nickel foams with pore per inch (PPI) higher than 90 as the catalysts, stable H2 production can be obtained. The reasons for obtaining the stable CMD are attributed to high surface area and catalyst active sites, better heat transfer characteristics, and enhanced Ni dispersion of Ni. For the reaction temperature of 900 °C and the nickel foam with a PPI of 110, the stable methane conversion of 90% can be obtained without COx production.

Integrated Thermal Management System Concept With Combined Jet Plate, High Porosity Aluminum Foam, and Target Plate for Enhanced Heat Transfer

Abstract An experimental investigation was carried out on high porosity metal foams subjected to array jet impingement with an objective to develop enhanced heat transfer configurations. In this study, we propose an integrated thermal management system (TMS) aimed toward leveraging the conjugate heat transfer capabilities of target plate, metal foam, and the jet plate—all made from aluminum and assembled such that a proper contact between them can be established. Steady-state heat transfer experiments were carried out for 10 and 20 pores per inch (PPI) aluminum foams of 0.93 porosity. Both metal foams were 12.7-mm thick. The normalized jet-to-jet spacing was varied from 2 to 12 times the jet diameter, while the jet diameter was fixed. The ratio of the jet plate thickness and jet diameter (nozzle aspect ratio) was 6.35, which ensured proper development of jets inside the nozzles. Experiments were conducted over a wide range of Reynolds number (based on jet diameter) varied from 100 to 5000. The obtained convective heat transfer coefficient for different configuration was evaluated in context with pressure drop. The analysis of experimental results reveal that large open area ratio jets combined with high porosity metal foams provide highly efficient and high-performance cooling for the investigated range of Reynolds numbers.

A porous media catalyst for waste polyethylene pyrolysis in a continuous feeding reactor

This study investigated the catalytic pyrolysis of waste polyethylene (PE) using a ZSM-5/Al2O3 porous media catalyst in a continuous feeding mode. The findings revealed that the porous media catalyst with 100 mm height and 40 PPI (pore per inch) pore size had the supreme catalytic performance, which could obtain the highest pyrolysis oil yield and the light fraction (<C12) and aromatics in the oil, and improve the catalytic stability of the porous media catalyst. The optimal operating conditions were the pyrolysis temperature of 460 °C, the carrier gas velocity of 65 mL/min, and the plastic feeding rate of 25 g/h, of which the light fraction and aromatics in the oil were up to 95.25 % and 97.33 %. Moreover, the catalytic cycling performance of the porous media catalyst was thoroughly investigated. The catalytic activity declined and the catalyst deactivation rate decreased after multiple regeneration cycles. This study presents a comprehensive investigation of waste PE catalytic cracking using the porous media catalyst in continuous feeding mode, which can provide insightful guidance on the industrialization of plastic waste valorization.

Experimental investigation of metal foam embedded surface thermal characteristics using air-jet impingement with different orifice geometry

Experimental investigation of metal foam embedded surface thermal characteristics using air-jet impingement with different orifice geometry

Carbon foam to enhance the performance of a slurry flow energy system used for hydrogen storage and transportation: An experimental investigation

A novel idea of using carbon foam (CF) is introduced to enhance the electrochemical performance of a slurry electrode system in a proton flow reactor system. Steam-activated and acid-washed Norit from peat is used as active charge carrier particles to prepare 15 wt% carbon slurry to be used in this study. The slurry flow rates in the experimental electrochemical system can be varied from 0 to 200 ml min−1, while using two channel widths of 1.6 cm and 2 cm to facilitate the slurry flow. Two sets of CFs with 10 pores per inch (PPI) and 5 PPI are used to understand the effect of introducing CFs with different pore sizes on the performance of slurry electrode. Slurry is charged slurry up to 100 C under constant application of 10 mA and 30 mA. After adding CF, the results show a significant drop in charging potential to generate both levels of current of 25% after using 5 PPI and 41% with 10 PPI. Furthermore, using the narrow channel flow of 1.6 cm and increasing the slurry flow rate from 100 ml min−1 to 150 ml min−1 lower the charging potential considerably by 19% and 21% (compared to base slurry) for 5 PPI and 10 PPI CF, respectively. Application of CF further enables the system to attain higher discharging time during the discharge cycle, and a maximum of 336% and 115% discharging capacity improvement is observed with 10 PPI and 5 PPI CF, respectively.

Explosion behavior of nonuniform hydrogen/methane/air mixtures in the presence of copper foam

The effect of copper foam on the explosion characteristics of nonuniform hydrogen/methane/air mixtures with different hydrogen volume fractions (φ) and diffusion times (DT) was investigated in a closed duct. Copper foams with different PPIs (pores per inch): 0 PPI, 20 PPI, 40 PPI, and 60 PPI were used, where 0 PPI refers to the case where there is no copper foam in the duct. The results show that a triple flame is observed in nonuniformly mixed hydrogen/methane/air mixtures after the hemispherical flame and finger flame stage, rather than the traditional plane flame and successive tulip flames. Upstream of the copper foam, the presence of the copper foam has no effect on the flame evolution process in uniformly mixed hydrogen/methane/air mixtures but affects the shape of the triple flame in nonuniformly mixed gas. The flame front develops numerous folds and cellular structures after it through the copper foam, and the flame velocity and overpressure increase rapidly. When the PPI of the copper foam is increased, the flame downstream of the copper foam becomes more disordered and irregular, and the maximum flame velocity and maximum overpressure initially increase and then decrease with increasing PPI. The maximum flame velocity and maximum overpressure are obtained in uniform and nonuniform hydrogen/methane/air mixtures when copper foams with 20 PPI and 40 PPI are used, respectively. The results provide experimental evidence for preventing and controlling hydrogen/methane fuel explosions.

Experimental studies on simultaneously reducing flow drag and noise of a circular cylinder with a downstream porous material plate

Pressure drag and noise level are two key parameters related to flow past a bluff body, thus various active and passive methods have been developed to reduce the drag and noise. The paper presents a passive method of simultaneously reducing the pressure drag and aerodynamic noise associated with flow past a smooth circular cylinder by placing a porous material plate (PMP) downstream the cylinder. Multi-points instantaneous wall pressure and far-field acoustic pressure have been measured in an anechoic wind-tunnel facility. The experimental results confirm that the PMP is effective to reduce both the pressure drag and the noise level, showing an attractive advantage compared with the impermeable splitter plate and porous coating. Parametric studies reveal effects of the pores per inch (PPI) of PMP, PMP-cylinder spacing and incoming flow velocity on the pressure drag and noise level.

Effect of polyurethane foam and carbon dioxide on the suppression of hydrogen/air explosion

This study examines the influence of polyurethane porous materials and carbon dioxide on hydrogen/air explosions within an enclosed vessel. Through analysis of peak overpressure, maximum rate of pressure rise, and shock wave propagation velocity, the suppression effects on explosions in hydrogen-air mixtures with different equivalence ratios at room temperature and atmospheric pressure are investigated. Findings indicate that porous materials with a PPI (pores per inch) of 60 significantly mitigate hydrogen/air explosions across all equivalence ratios. Conversely, a PPI below 60 exacerbates the explosions. Simultaneous presentation of PPI60 porous material and a CO2 addition level of x = 2 (carbon dioxide to oxygen ratio) reduces hydrogen explosion pressure to only 13.7 kPa at "Φ = " 1.2, representing an attenuation rate of 84% and falling well below the human safety threshold of 28 kPa. Independent effects of carbon dioxide and porous materials on hydrogen explosions across various equivalence ratios are also explored. The experimental design encompasses a broad range of equivalence ratios, covering hydrogen's explosive limits. These results contribute to the design of flame arrestors and enhance understanding of explosion suppression in hydrogen systems.

The Effect of Uneven Metal Foam Distribution on Solar Compound Parabolic Trough Collector Receiver Thermal Performance

Solar energy is a key player among other renewable energies that reduce greenhouse gases and replace conventional fuel, i.e., to solve global warming and fossil fuel descending issues. However, the thermal solar systems’ performance should be enhanced to cope with intermittent solar radiation. Metal foam can be used as an enhancer in solar collectors’ receivers. However, metal foams are associated with pressure drop. To benefit from the metal foam as a thermal enhancer and overcome the pressure drop issue, the present study numerically and experimentally investigates a novel Compound Parabolic Solar Collector (CPC) receiver with innovative uneven metal foam inserts of varying thickness. Two pores per inch (PPI) Cu-foam inserts, PPI10 and PPI20, were tested. These inserts were strategically placed at three different positions along the receiver, with thicknesses of 3 cm, 2 cm, and 1 cm starting from the inlet side. In the experimental part, three tubular receivers were tested, empty, i.e., without metal foam, inserted with Cu-foam of PPI10, and inserted with Cu-foam of PPI20. The experiments were conducted from 09:00 AM to 04:00 PM. The investigation involved water volume flow rates from 0.2 to 0.6 l/min. The numerical part included solving the governing equations, i.e., mass, momentum, and energy conservation, simulating conditions similar to the experiments. The Brinckman model described the fluid flow through the metal foam. The thermal performance of the CPC system was evaluated using the Nusselt number (Nu), thermal efficiency, water bulk temperature, and water outlet-inlet temperature difference. Inserting Cu-foam of PPI20 resulted in the hourly maximum Nu and thermal efficiency compared to the empty and PPI10 cases. Experimentally, the hourly maximum Nu was 8.9, 8.4, and 7.9 for PPI20, PPI10, and empty receivers, respectively, at 0.6 l/min. The average thermal efficiency was 88.3, 85, and 81.9 for PPI20, PPI10, and empty receivers, respectively, at 0.6 l/min. As for the outlet-inlet water temperature difference, the highest values were at 0.2 l/min. Again, PPI20 recorded the best results, i.e., 23.3 K, 21.5 K, and 20.2 K for PPI20, PPI10, and empty cases, respectively.