Case Studies in Thermal Engineering最新文献

{"title":"Dual enhancement of solar distiller using phase change material and internal fans: An experimental 11-E study for sustainable water production","authors":"A.E. Kabeel ,&nbsp;Khaled Ramzy ,&nbsp;Abdulrhman Alshaabani ,&nbsp;Eslam Ahmed abdelAziz ,&nbsp;Mohamed Bassyouni ,&nbsp;Mohamad A. Alawad","doi":"10.1016/j.csite.2026.107882","DOIUrl":"10.1016/j.csite.2026.107882","url":null,"abstract":"<div><div>This research conducts a comprehensive experimental study of a solar distillation configuration enhanced with phase change material and internal electric fans, in a single-slope solar stills. Despite their operational simplicity, conventional single-slope solar stills are fundamentally limited by low distillate yields due to significant thermal losses and the formation of a stagnant vapor boundary layer that impedes efficient mass transfer. An experimental arrangement was constructed and tested at Faculty of Engineering, Sinai University, Egypt, and analyzed using 11-E framework, which encompasses assessments of energetic, exergetic, economic, environmental, and sustainability aspects. Four operating scenarios were examined: (i) conventional solar still (CSS), (ii) Enhanced solar still with fans only (ESSF), (iii) Enhanced solar still with paraffin wax only (ESSP), and (iv) Enhanced solar still with both paraffin wax and fans (ESSPF). The results indicated that integrating PCM beneath the absorber plate extended operation into post-sunset hours by providing latent heat storage. At the same time, fans improved internal convection, accelerated vapor transport, and enhanced condensation. The combined configuration (ESSPF) yielded the highest performance, with a supreme daily freshwater productivity of 5.26 ± 0.01 kg/m², representing an 87.90 ± 0.01% increase compared with the conventional one. Energy and exergy productivity rates for ESSPF reached 49 ± 0.05% and 2.0 ± 0.05%, respectively, while the water production cost decreased to 0.00772 $/L, resulting in a reduced payback period of 5.25 months. An environmental analysis confirmed a substantial decrease in CO₂ emissions resulting from a decrease in dependence on traditional fuel-based water production. Furthermore, sustainability and improvement potential indices indicated that the enhanced stills provide a more viable long-term solution. Overall, the integration of paraffin wax and internal fans provides a cost-effective, reliable, and scalable modification to conventional solar stills, supporting global strategies for sustainable and environmentally friendly water desalination.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107882"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147330037","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study on structural design and heat transfer characteristics of biomimetic honeycomb heat exchanger","authors":"Yixin Zhang ,&nbsp;Bao Meng ,&nbsp;Jinquan Han ,&nbsp;Yu Zhu ,&nbsp;Min Wan","doi":"10.1016/j.csite.2026.107881","DOIUrl":"10.1016/j.csite.2026.107881","url":null,"abstract":"<div><div>With the continuous rise in the power of chips for electric vehicle controllers, traditional air or liquid cooling can no longer meet the current heat dissipation requirements of such controllers. To meet the thermal management requirements of electric vehicle controllers, this study designs and optimizes a novel biomimetic honeycomb microchannel heat exchanger (HMHE) based on the leaf vein fractal network and honeycomb structure. Computational Fluid Dynamics (CFD) was employed to establish the simulation model of HMHE, and the effects of honeycomb grade, channel width ratio (<em>r</em>_<em>c</em>), channel width (<em>a</em>_<em>1</em>) and channel depth (<em>H</em>_<em>ch</em>) on the performance of HMHE were investigated. The comprehensive performance of HMHEs was compared using Figure of Merit (<em>FOM)</em>, determining that the three-level Honeycomb Microchannel Heat Exchanger (L3-HMHE) exhibits the optimal performance. Meanwhile, through single-parameter optimization, it was confirmed that the optimal structural parameter range of L3-HMHE is around <em>r</em>_<em>c</em> = 0.9, <em>a</em>_<em>1</em> = 8 mm and <em>H</em>_<em>ch</em> = 18 mm. Based on the optimization strategy combined with the Response Surface Methodology (RSM), a quantitative correlation model between the structural parameters of L3-HMHE and <em>FOM</em> was established. It was found that the channel width has the most significant impact on the comprehensive performance of the heat exchanger, while the optimal channel structural parameters are <em>r</em>_<em>c</em> = 0.8, <em>a</em>_<em>1</em> = 9 mm and <em>H</em>_<em>ch</em> = 18 mm, respectively. By comparing the results of numerical simulations and actual experiments, the temperature performance errors and pressure drop errors of the L3-HMHE between numerical simulations and actual experiments are maintained within 6.5% and 11%, respectively, at the load powers of 100 W, 120 W and 140 W, which validates the established numerical simulation model of the L3-HMHE. The <em>FOM</em> of the optimized L3-HMHE reaches 1.283, representing a 77.2% improvement compared with the traditional U-shaped heat exchanger, and it can satisfy the heat transfer requirements under a stable heat generation power of 200 W. The research results provide new insights into the structural design of HMHEs and promote the application of L3-HMHEs in the thermal management of electric vehicle controllers.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107881"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147330098","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Performance and energy implications of a reconfigurable multi-mode dehumidification and reheating heat pump for electric vehicles","authors":"Haifeng Lu ,&nbsp;Dandong Wang ,&nbsp;Junye Shi ,&nbsp;Yuan Pan ,&nbsp;Mingli Shang ,&nbsp;Jiangping Chen ,&nbsp;Zhongqin Lin","doi":"10.1016/j.csite.2026.107883","DOIUrl":"10.1016/j.csite.2026.107883","url":null,"abstract":"<div><div>The performance of heat pump air-conditioning systems is crucial for electric vehicles (EVs), particularly under cold and humid conditions, where maintaining cabin comfort while minimizing energy consumption is a significant challenge. However, existing systems often suffer from an energy trade-off between dehumidification and reheating, leading to high energy consumption and reduced driving range in such environmental conditions. In this study, a multi-mode heat pump dehumidification and reheating system for EVs was developed, integrating four operational modes—Parallel Evaporator Dehumidification Mode (PEDM), Parallel Condenser Dehumidification Mode (PCDM), Whole Series Dehumidification Mode (WSDM), and Partial Series Dehumidification Mode (PSDM)—controlled by dynamic refrigerant flow regulation through solenoid valves and electronic expansion valves. A high-fidelity model was developed in AMESim and validated across a wide temperature range from −10 °C to 25 °C, coupled with a vehicle-level energy flow model for evaluating the effects on HVAC and overall vehicle energy consumption under the Worldwide harmonized Light-duty Test Cycle (WLTC).The results indicate that PEDM achieves the highest dehumidification coefficient of performance (DHCOP) and the lowest HVAC energy consumption (20.4 Wh/km), improving driving range by 11% compared to conventional single-mode systems. PCDM, while offering the highest moisture extraction rate (MER), incurs significantly higher energy consumption (45.5 Wh/km). WSDM strikes a balance between energy efficiency and performance (22.6 Wh/km), while PSDM operates stably but with lower efficiency. The study provides valuable insights into the coupling mechanism between dehumidification performance and vehicle energy flow, laying a foundation for designing adaptive, energy-efficient heat pump systems for EVs in cold and humid environments.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107883"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147359840","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimization of a gas–steam–power system linked with energy storage devices in steel enterprises","authors":"Wei Tan ,&nbsp;Xin Liu ,&nbsp;Fupeng Song ,&nbsp;Dong Wang ,&nbsp;Zhaoyi Huo ,&nbsp;Zhuo Yao ,&nbsp;Yixuan Han ,&nbsp;Xiaoling Zhang","doi":"10.1016/j.csite.2026.107889","DOIUrl":"10.1016/j.csite.2026.107889","url":null,"abstract":"<div><div>In the \"dual-carbon\" strategy, steel enterprises' energy systems meet changeable electricity demand and rigorous carbon emission rules. This study integrates several types and scales of energy storage devices while optimizing a gas–steam–electric multi-energy network. A mixed integer non-linear programming (MINLP) approach is applied to generate an ideal strategy for energy storage arrangement and a dynamic scheduling technique. Four scenarios are evaluated: Scenario C1 serves as the initial optimal design; Scenario C2 builds on C1 by incorporating molten salt (MS) energy storage device (ESD) with a 25 MW generator set; Scenario C3 incorporate thermal conductive oil (TCO) ESD with a combined cycle power plant (CCPP); and Scenario C4 builds upon C2 by coupling MS–ESD of different scales with CCPP. Comparing scenario C4 with C1, it can be concluded that through ESD configuration, single-objective optimization yields monthly economic benefits of 2.45 × 10⁵ CNY. The C2 scenario enhances the high-efficiency unit's operating ratio through dynamic fuel allocation. Scenario C3 reduces the pressure on the power grid during peak electricity consumption periods. Using multi–objective optimization, ESD can achieve a cumulative economic benefit of 3.15 × 10⁷ CNY and an emission reduction of 3.41 × 10⁵ t_CO2 during its lifetime. Through detailed analysis of multi-scenario and multi-cycle optimization results, ESD-1 improves energy efficiency through fuel redistribution, and ESD-2 mainly plays the role of power peaking.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107889"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147387372","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Waste-to-energy in CRDI engines: A case study on optimized biodiesel-ethanol-TBHQ blends for enhanced thermal performance and reduced emissions","authors":"Manish Kumar,&nbsp;Naushad Ahmad Ansari,&nbsp;Raghvendra Gautam","doi":"10.1016/j.csite.2026.107907","DOIUrl":"10.1016/j.csite.2026.107907","url":null,"abstract":"<div><div>Integrating waste-derived biofuels into common rail direct injection (CRDI) diesel engines presents a thermal engineering challenge in balancing performance and emissions while promoting circular economy principles. This case study investigates a novel blend of waste cooking oil and plastic oil biodiesel, ethanol, and tert-butyl hydroquinone (TBHQ) in a CRDI diesel engine. A hybrid Response Surface Methodology (RSM) and Grey Relational Analysis (GRA) framework optimized engine characteristics for performance and emissions. The optimized blend demonstrated improved brake thermal efficiency (15.17%) and exhaust gas temperature (168.27 °C), alongside significant reductions in CO (0.307% vol.), HC (29.05 ppm), and smoke opacity (15.37%). Crucially, while NO_x emissions (262 ppm) remained a challenge, TBHQ effectively mitigated oxidation-driven spikes, showcasing a targeted solution within this specific thermal system. Model robustness was confirmed with high statistical significance (R² &gt; 0.97) and low experimental validation errors (&lt;5%). This study, by integrating waste-derived feedstock, strongly aligns with circular economy goals, reducing reliance on petroleum oils. It offers a replicable, validated framework for multi-objective optimisation in sustainable thermal energy systems. Practical implications include enhanced urban air quality and a pathway for industries to meet stringent environmental regulations, accelerating sustainable biodiesel adoption in power sectors.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107907"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147387373","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Computational and experimental investigation of thermoelectric generators in series-parallel configurations under variable resistive loads and temperature gradients","authors":"Roshan Manghwar ,&nbsp;Jeyraj Selvaraj ,&nbsp;Hafeez Khoharo ,&nbsp;Laveet Kumar ,&nbsp;Muhammad Shakeel Ahmad","doi":"10.1016/j.csite.2026.107913","DOIUrl":"10.1016/j.csite.2026.107913","url":null,"abstract":"<div><div>Thermoelectric generation is a potential technology for waste heat recovery, however, increase in the internal resistance is one of the key parameters limiting its utilization for scalable applications. Previous research in this domain is limited to the thermoelectric elements and modules. Current research focuses on the performance evaluation of thermoelectric generators under variable resistive loads and temperature gradients in different configurations. Computational modelling of the thermoelectric generator has been performed using fully coupled steady-state model in conjunction with experimental research to validate the results. Results were acquired under varying temperature gradients and resistive loads between 1Ω and 30Ω and extended up to 40Ω for eight modules in series. The system is analyzed experimentally through natural convective cooling for variable resistive load maintained at constant temperature, and the reverse scenario is also considered. The maximum power generated from a single thermoelectric module is 1.69W at 5Ω resistive load. This value corresponds to the temperature difference of 100 °C and surpasses the experimental value by 6.29%. The study computationally evaluates thermoelectric performance of two, four, and eight modules in both series and parallel arrangements. The power output for eight modules configured in series, parallel, and hybrid arrangement was measured as 13.53W, 12.60W, and 13.55W, respectively, and efficiency was determined as 3.79%, 3.77%, and 3.84% respectively. The comparative results highlight optimal performance of thermoelectric generators in series &amp; parallel hybrid arrangement. Study represents low grade waste heat recovery potential from coal fired power plants and oil and gas sector.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107913"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147387426","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Numerical optimization by deep single selective investigation and experimental validation for star-fin inserts in absorber tubes","authors":"Zeki Ali Al-Saadi ,&nbsp;Adnan Ibrahim ,&nbsp;Firas Abdulamir Radhi ,&nbsp;Yassine El Alami ,&nbsp;Anwer B. Al-Aasam ,&nbsp;Rasha Abdulrazzak Jasim ,&nbsp;Sharul Sham Dol ,&nbsp;Mohammed Ghazal ,&nbsp;Ahmad Fazlizan","doi":"10.1016/j.csite.2026.107930","DOIUrl":"10.1016/j.csite.2026.107930","url":null,"abstract":"<div><div>Limited thermal efficiency remains a persistent challenge in the design of modern heat exchangers employing absorber tubes. This study addresses this limitation by integrating geometric fin optimization with nanofluid enhancement to maximize the thermal-hydraulic performance factor (THPF). A novel star-finned copper absorber tube was designed for turbulent flow conditions. The optimization was carried out using the Deep Single-Selective Investigation (DSSI) methodology, considering five key geometric parameters: fin edge number (2-5), fin diameter (14-15.5 mm), fin thickness (2-3.5 mm), number of fins per rod (4-8), and angular spacing (0-40°). The analysis was conducted under hydraulic and geometric constraints, with Reynolds numbers ranging from 6000 to 15,000 and a fixed absorber tube diameter of 19.10 mm. The optimal configuration consisted of a five-edge fin with a 15.5 mm diameter, six fins per rod, a thickness of 3 mm, and an angular spacing of 30°. Numerical results showed THPF values of 1.856 with distilled water and 2.100 with the 0.2% Al₂O₃ nanofluid, demonstrating the enhanced THPF compared with a smooth tube baseline. Experimental validation yielded THPF values of 1.834 with distilled water and 2.004 with the nanofluid. CFD predictions matched experiments (R² = 0.9982, RMSE = 2.42), confirming the robustness of the framework and supporting the applicability of the proposed design for advanced thermal systems.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107930"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147387428","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Assessment of fire flow demand in Chinese traditional villages based on UAV photogrammetry and fire propagation analysis","authors":"Feiyang Zheng,&nbsp;Zhigang Song,&nbsp;Jian Zhang,&nbsp;Jinsheng Han","doi":"10.1016/j.csite.2026.107841","DOIUrl":"10.1016/j.csite.2026.107841","url":null,"abstract":"<div><div>Chinese traditional villages are generally exposed to severe risks of fire propagation. Against this background, the scientific and rational estimation of fire flow demand is not only a key basis for evaluating whether existing water-supply conditions can meet firefighting requirements but also a prerequisite for developing effective suppression and protection strategies. This study develops an efficient and cost-effective framework for assessing fire flow demand in traditional villages. First, unmanned aerial vehicle (UAV) oblique photogrammetry combined with on-site surveys was used to obtain the external parameters and internal features of buildings, which were then used to identify fire propagation pathways between buildings. Then, the fire flow demand for each building was calculated individually, distinguishing between offensive operations (extinguishing the fire source) and defensive operations (protecting adjacent buildings). The resulting distribution of fire flow demand across buildings was used to estimate the total fire flow demand of the village. Finally, the proposed framework was applied to calculate the fire flow demand of eleven representative traditional villages in Yunnan Province, followed by a comparison with current codes. The comparison reveals that the design flow rates of existing integrated water-supply systems are insufficient to meet the firefighting needs of traditional villages fully. Furthermore, correlation analysis reveals that offensive fire flow demand is primarily influenced by building volume, whereas defensive fire flow demand is associated with spatial connectivity and separation distance.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107841"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146777431","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Lightweight concrete with improved thermomechanical properties incorporating PCM-infused microsilica additives","authors":"Mahshid Abdoli,&nbsp;Davood Mostofinejad,&nbsp;Amin Karimi,&nbsp;Alireza Saljoughian,&nbsp;Mohammadreza Eftekhar","doi":"10.1016/j.csite.2026.107837","DOIUrl":"10.1016/j.csite.2026.107837","url":null,"abstract":"<div><div>The increasing need for environmentally sustainable building materials has positioned lightweight concrete (LWC) as a promising solution, offering benefits such as reduced weight and improved thermal and acoustic properties. However, previous studies indicate that incorporating lightweight aggregates (LWA) into LWC can adversely affect the material's mechanical properties. Furthermore, the potential integration of phase-change materials (PCMs) in LWC remains largely unexplored, particularly under challenging environmental conditions. To address these gaps, this study investigates the controlled use of lightweight expanded clay aggregate (LECA) and micro-silica infused with polyethylene glycol (PEG) 600 and 1000 as PCMs to develop LWC with superior mechanical and thermal properties. A novel “simulated solar exposure and moisture conditioning test” and a thermal behavior evaluation test are introduced. Additional mechanical and thermal tests, including measurements of compressive strength and thermal conductivity, were conducted to optimize LWC properties for warm, humid climates. The results indicate that, although water absorption increased with higher LECA contents, PEG 1000 reduced it by 67%. Thermal conductivity decreased with increasing LECA content and further decreased with PEG 1000 infusion, achieving a 64% reduction. The sunlight and humidity simulation test also demonstrated the superior thermal stability of PEG 1000-infused mixtures. These findings highlight the potential of PCM-integrated LWC to enhance energy efficiency and thermal performance, offering significant advancements for sustainable building design.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107837"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146778093","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Numerical simulation on flow regulation and heat transfer characteristics of embedded adaptive pin-fin microchannel heat sinks under non-uniform heat sources","authors":"Linzheng Fu,&nbsp;Jing Wen,&nbsp;Yiou Qiu,&nbsp;Ping Wu,&nbsp;Liancheng Wang,&nbsp;Wenhui Zhu","doi":"10.1016/j.csite.2026.107847","DOIUrl":"10.1016/j.csite.2026.107847","url":null,"abstract":"<div><div>This work proposes an adaptive pin-fin microchannel cooling configuration that employs the thermally responsive deformation of hydrogel pin-fins to manage the transient and spatially uneven thermal loads generated during chip operation. Temperature-driven volumetric changes in the hydrogel structures enable continuous adjustments of coolant passage geometry, allowing the system to redistribute flow locally and achieve self-regulating thermal control. A dynamic-mesh numerical approach is developed to characterize pin-fin deformation under high heat-flux conditions and to evaluate its impact on flow behavior and heat dissipation. Compared with non-adaptive microchannel heat sink (N-MCHS), the adaptive design (A-MCHS) demonstrates distinctly improved coolant routing and enhanced thermal performance. Under a single-hotspot condition with a heat flux of 100 W/cm², the A-MCHS lowers the peak hotspot temperature by 7.5 K and reduces the pressure drop by 44.4%, while requiring only 2.26 mW of pumping power. The corresponding Nusselt numbers (<em>Nu</em>) for A-MCHS and N-MCHS are 7.36 and 5.68, respectively, confirming the superior heat transfer capability and low energy demand of the adaptive configuration. The system also maintains effective temperature suppression when multiple hotspots are present. Additionally, as the Reynolds number (<em>Re</em>) increases, the A-MCHS consistently achieves lower hotspot temperatures and reduced thermal non-uniformity relative to the N-MCHS, highlighting its stable thermal regulation behavior. Overall, the proposed adaptive microchannel structure provides a promising route toward efficient, low-power, and self-adjusting cooling solutions for chips operating under dynamically evolving heat flux conditions.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"80 ","pages":"Article 107847"},"PeriodicalIF":6.4,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146778512","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}