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JOINING TECHNIQUES FOR NOVEL METAL POLY MER HYBRID HEAT EXCHANGERS

Conference ·
OSTI ID:1577136
 [1];  [2];  [2];  [2];  [2];  [2];  [2];  [2];  [2];  [2];  [2];  [2]
  1. Univ. of Illinois at Urbana-Champaign, IL (United States); University of Illinois at Urbana-Champaign
  2. Univ. of Illinois at Urbana-Champaign, IL (United States)
+ Show Author Affiliations

In the United States, over 50% of the unrecovered e nergy from industrial processes is in the form of low- grade heat (<220°C). Materials and maintenance co sts of common heat exchangers are typically too hig h to justify their usage. Polymers, though more afford able, are usually unsuitable for HX applications due t o their low thermal conductivity (~0.2 W/mK). Here, we show that metal-polymer hybrids may be attractiv e from both performance and cost perspectives. The use of polymers further increases the resistance to c orrosion by sulfuric and carbonic acids often present in flue gases. An ongoing work explores different co nfigurations of layered polyimide-copper macroscale hybrids for heat exchanger applications using numeri cal simulations. This paper explores a manufacturing pathway for producing such layered hybrid tubes tha t involves directly rolling and bonding tapes made of polymer and copper foil into tubes. A critical problem in the fabrication process is the bonding of metal and polymers. We explore approaches involving adhesiv es (epoxy, acrylic and silicone) for metal/polymer inte rfaces and direct welding (ultrasonic) for metal/metal interfaces that can be integrated into the manufacturi ng process. We report characterizations of the therm omechanical properties of these joining processes. T his work paves the way for realizing cost-effective m anufacturing of heat exchangers for low grade waste heat recovery.

Research Organization:
University of Illinois
Sponsoring Organization:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A)
DOE Contract Number:
EE0008312
OSTI ID:
1577136
Report Number(s):
DOE-UIUC-0008312-7
Country of Publication:
United States
Language:
English

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