Thermo-fluidic comparison between sandwich panels with tetrahedral lattice cores fabricated by casting and metal sheet folding

This numerical study compares single-phase forced convective heat transfer between two sandwich panels with tetrahedral metallic lattice cores separately fabricated by investment casting and the more cost-effective metal sheet folding method. The numerical model is validated against available experimental data. For a given Reynolds number and core porosity, the results reveal that the brazed sandwich outperforms the casted sandwich, exhibiting a 13% to 16% higher Nusselt number. Bigger vertexes and more evident blockage of mainstream by the ligaments are found to intensify the horseshoe vortex and the counter-rotating vortex pair upstream and downstream of each vertex. Relative to the casted sandwich panel, therefore, endwall heat transfer is enhanced by 22% to 27%, while similar heat transfer is achieved on the ligaments. It is also found that, for a given Reynolds number, the brazed sandwich induces a 1.6 to 1.7 times higher pressure drop relative to the casted sandwich due to more severe flow separation caused by the sharp edges of the rectangular ligaments. Finally, for a given pumping power, both sandwiches provide a similar heat transfer performance. Given that the brazed sandwich is more cost-effective and easier to fabricate than the casted one, the former may be superior from an engineering application point of view.