{"id":{"repo_id":"uiuc","oai_identifier":"oai:www.ideals.illinois.edu:2142/107835"},"canonical_url":"https://search.dev.ndltd.org/etd/uiuc/oai:www.ideals.illinois.edu:2142/107835","repository":{"repo_id":"uiuc","name":"University of Illinois - Urbana-Champaign","base_url":"https://www.ideals.illinois.edu/oai-pmh"},"display":{"title":"Design and manufacturing of novel hybrid metal-polymer heat exchangers","abstract":"In the United States, over 50% of the unrecovered energy from industrial processes is in the form of low-grade heat (200◦C). Materials and maintenance costs of common heat exchangers are typically too high to justify their usage. Polymers, though more affordable, are usually unsuitable for heat exchanger applications due to their low thermal conductivity (∼ 0.2 W/mK). Here, we show that metal-polymer hybrids may be attractive from both performance and cost perspectives. The use of polymers further increases the resistance to corrosion by sulfuric and carbonic acids often present in flue gases. This work explores manufacturing different configurations of layered polyimide-copper macroscale hybrids for heat exchanger applications using a modified roll to roll process. We created a manufacturing pathway for producing such layered hybrid tubes that 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 adhesives (epoxy, acrylic , and silicone) for metal/polymer interfaces and direct welding (ultrasonic) for metal/metal interfaces that can be integrated into the manufacturing process. We report characterisations of the thermomechanical properties of these joining processes. This work paves way for realizing cost effective manufacturing of heat exchangers for low-grade waste heat recovery.","abstract_html":"In the United States, over 50% of the unrecovered energy from industrial processes is in the form of low-grade heat (200◦C). Materials and maintenance costs of common heat exchangers are typically too high to justify their usage. Polymers, though more affordable, are usually unsuitable for heat exchanger applications due to their low thermal conductivity (∼ 0.2 W/mK). Here, we show that metal-polymer hybrids may be attractive from both performance and cost perspectives. The use of polymers further increases the resistance to corrosion by sulfuric and carbonic acids often present in flue gases. This work explores manufacturing different configurations of layered polyimide-copper macroscale hybrids for heat exchanger applications using a modified roll to roll process. We created a manufacturing pathway for producing such layered hybrid tubes that 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 adhesives (epoxy, acrylic , and silicone) for metal/polymer interfaces and direct welding (ultrasonic) for metal/metal interfaces that can be integrated into the manufacturing process. We report characterisations of the thermomechanical properties of these joining processes. This work paves way for realizing cost effective manufacturing of heat exchangers for low-grade waste heat recovery.","abstract_has_math":false,"creators":["Kuntumalla, Gowtham"],"institution":"University of Illinois at Urbana-Champaign","degree_name":"M.S.","degree_level":"Thesis","degree_discipline":"Mechanical Engineering","degree_department":null,"school":null,"contributors":["Sinha, Sanjiv"],"advisors":[],"committee_chairs":[],"committee_members":[],"year":2020,"date_issued":"2020-04-03","date_published":"2020-04-03","updated_at":"2026-07-22T22:24:47Z","subjects":["copper, polymer, kapton, joining techniques, adhesives, dissimilar materials, heat exchangers, roll-to-roll process, waste heat recovery"],"languages":["en"],"rights":["Copyright 2020 Gowtham Kuntumalla"],"rights_urls":[],"identifier_entries":[]},"links":{"outbound_url":"http://hdl.handle.net/2142/107835","outbound_label":"Handle","outbound_source":"dc:identifier"},"metadata_groups":[{"id":"people","label":"People","entries":[{"key":"dc:contributor","label":"Contributor","values":["Sinha, Sanjiv"]},{"key":"dc:creator","label":"Author","values":["Kuntumalla, Gowtham"]}]},{"id":"academic_context","label":"Academic Context","entries":[{"key":"dc:date","label":"Dc Date","values":["2020-04-03","2020-05","2020-08-26T21:53:52Z"]},{"key":"dc:type","label":"Dc Type","values":["text","Thesis"]},{"key":"thesis:degree_discipline","label":"Discipline","values":["Mechanical Engineering"]},{"key":"thesis:degree_level","label":"Degree Level","values":["Thesis"]},{"key":"thesis:degree_name","label":"Degree Name","values":["M.S."]},{"key":"thesis:institution_name","label":"Thesis Institution Name","values":["University of Illinois at Urbana-Champaign"]}]},{"id":"subjects_keywords","label":"Subjects and Keywords","entries":[{"key":"dc:subject","label":"Dc Subject","values":["copper, polymer, kapton, joining techniques, adhesives, dissimilar materials, heat exchangers, roll-to-roll process, waste heat recovery"]}]},{"id":"language_rights","label":"Language and Rights","entries":[{"key":"dc:language","label":"Dc Language","values":["en"]},{"key":"dc:rights","label":"Dc Rights","values":["Copyright 2020 Gowtham Kuntumalla"]}]},{"id":"identifiers","label":"Identifiers","entries":[{"key":"dc:identifier","label":"Identifier","values":["http://hdl.handle.net/2142/107835"]}]},{"id":"additional","label":"Additional Metadata","entries":[{"key":"dc:description","label":"Description","values":["In the United States, over 50% of the unrecovered energy from industrial processes is in the form of low-grade heat (200◦C). Materials and maintenance costs of common heat exchangers are typically too high to justify their usage. Polymers, though more affordable, are usually unsuitable for heat exchanger applications due to their low thermal conductivity (∼ 0.2 W/mK). Here, we show that metal-polymer hybrids may be attractive from both performance and cost perspectives. The use of polymers further increases the resistance to corrosion by sulfuric and carbonic acids often present in flue gases. This work explores manufacturing different configurations of layered polyimide-copper macroscale hybrids for heat exchanger applications using a modified roll to roll process. We created a manufacturing pathway for producing such layered hybrid tubes that 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 adhesives (epoxy, acrylic , and silicone) for metal/polymer interfaces and direct welding (ultrasonic) for metal/metal interfaces that can be integrated into the manufacturing process. We report characterisations of the thermomechanical properties of these joining processes. This work paves way for realizing cost effective manufacturing of heat exchangers for low-grade waste heat recovery.","Submission original under an indefinite embargo labeled 'Open Access'. The submission was exported from vireo on 2020-08-25 without embargo terms","The student, Gowtham Kuntumalla, accepted the attached license on 2020-04-01 at 12:46.","The student, Gowtham Kuntumalla, submitted this Thesis for approval on 2020-04-01 at 12:51.","This Thesis was approved for publication on 2020-04-03 at 16:10.","DSpace SAF Submission Ingestion Package generated from Vireo submission #14642 on 2020-08-25 at 17:02:46","Made available in DSpace on 2020-08-26T21:53:52Z (GMT). No. of bitstreams: 2 KUNTUMALLA-THESIS-2020.pdf: 5896497 bytes, checksum: 4f1e4aaeb4c5c86d0c0492b8f8914ec8 (MD5) LICENSE.txt: 4215 bytes, checksum: beb0021128b22bbcdab8ae44dacca70d (MD5) Previous issue date: 2020-04-03"]},{"key":"dc:format","label":"Dc Format","values":["application/pdf"]},{"key":"dc:title","label":"Title","values":["Design and manufacturing of novel hybrid metal-polymer heat exchangers"]}]}],"canonical_facts":{"dc:contributor":["Sinha, Sanjiv"],"dc:creator":["Kuntumalla, Gowtham"],"dc:date":["2020-04-03","2020-05","2020-08-26T21:53:52Z"],"dc:description":["In the United States, over 50% of the unrecovered energy from industrial processes is in the form of low-grade heat (200◦C). Materials and maintenance costs of common heat exchangers are typically too high to justify their usage. Polymers, though more affordable, are usually unsuitable for heat exchanger applications due to their low thermal conductivity (∼ 0.2 W/mK). Here, we show that metal-polymer hybrids may be attractive from both performance and cost perspectives. The use of polymers further increases the resistance to corrosion by sulfuric and carbonic acids often present in flue gases. This work explores manufacturing different configurations of layered polyimide-copper macroscale hybrids for heat exchanger applications using a modified roll to roll process. We created a manufacturing pathway for producing such layered hybrid tubes that 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 adhesives (epoxy, acrylic , and silicone) for metal/polymer interfaces and direct welding (ultrasonic) for metal/metal interfaces that can be integrated into the manufacturing process. We report characterisations of the thermomechanical properties of these joining processes. This work paves way for realizing cost effective manufacturing of heat exchangers for low-grade waste heat recovery.","Submission original under an indefinite embargo labeled 'Open Access'. The submission was exported from vireo on 2020-08-25 without embargo terms","The student, Gowtham Kuntumalla, accepted the attached license on 2020-04-01 at 12:46.","The student, Gowtham Kuntumalla, submitted this Thesis for approval on 2020-04-01 at 12:51.","This Thesis was approved for publication on 2020-04-03 at 16:10.","DSpace SAF Submission Ingestion Package generated from Vireo submission #14642 on 2020-08-25 at 17:02:46","Made available in DSpace on 2020-08-26T21:53:52Z (GMT). No. of bitstreams: 2 KUNTUMALLA-THESIS-2020.pdf: 5896497 bytes, checksum: 4f1e4aaeb4c5c86d0c0492b8f8914ec8 (MD5) LICENSE.txt: 4215 bytes, checksum: beb0021128b22bbcdab8ae44dacca70d (MD5) Previous issue date: 2020-04-03"],"dc:format":["application/pdf"],"dc:identifier":["http://hdl.handle.net/2142/107835"],"dc:language":["en"],"dc:rights":["Copyright 2020 Gowtham Kuntumalla"],"dc:subject":["copper, polymer, kapton, joining techniques, adhesives, dissimilar materials, heat exchangers, roll-to-roll process, waste heat recovery"],"dc:title":["Design and manufacturing of novel hybrid metal-polymer heat exchangers"],"dc:type":["text","Thesis"],"thesis:degree_discipline":["Mechanical Engineering"],"thesis:degree_level":["Thesis"],"thesis:degree_name":["M.S."],"thesis:institution_name":["University of Illinois at Urbana-Champaign"]},"updated_at":"2026-07-22T22:24:47Z"}