Optimization of permeable membrane microchannel heat sinks for additive manufacturing

The design freedom brought by additive manufacturing (AM) can be leveraged in the of microchannel heat sinks to improve their cooling performance. permeable membrane (PMM) sink geometry was inspired ability powder bed AM processes fabricate partially porous metal parts having small internal flow features on order size. routes coolant through a parallel array thin membranes arranged single-layer-manifold configuration. provide effective exchange surfaces and manifold configuration yields low resistance across PMM sink, all incorporated single layer use AM. Past work has introduced concept, but optimal geometric feature sizes were not explored or identified. n current study is first explore optimization identify target for fabrication, assessment conditions under which outperforms other standard designs, inspection 3D printing process produce features. To this end, reduced-order model developed, gradient-based-multi-objective performed different coolants (water 48/52 water/ethylene glycol mixture) at rates (100–500 mL/min), footprint areas (49–900 mm2), channel heights (0.5–2.5 mm). results are benchmarked against an optimized straight (SMC) design. Optimized designs offer up 68% lower thermal set pressure drop compared SMC designs. A pair same operating printed using direct-metal-laser-sintering (DMLS) AlSi10Mg. X-ray microtomography used characterize 3D-printed parts. identifies that gap ~ 10 s ?m required realize performance advantages conditions. predicted highly sensitive pore size, even though DMLS shown with gaps as 26.7 µm, morphological deviations between as-printed part lead noticeable differences. Albeit excellent potential reinforced work, these findings call further development ensure reliable, as-predicted potential.