February 5, 2015

Heat Transfer lab

Batch 1 - Roll Nos:14 to 19

EVALUATION OF OVERALL HEAT TRANSFER COEFFICIENT AND THERMAL

CONDUCTIVITY OF ALUMINIUM

Chintaginjala Dileep Kumar, Fahd Bin Abdul Hasis, Gautam Kumar Jha,
Ghosh Partho Shankar, Gowtham S, Himanshu Kumar
B.Tech, Fourth semester
Department of Aerospace Engineering
Indian Institute of Space Science and Technology

ABSTRACT by applying the Fourier law of heat conduction.

The experiment was conducted to determine the thermal
conductivity of a sample by using an idealized one-dimensional
conducting apparatus. The sample having unknown conductivity
was placed in between two metal pieces having known conductiv-
ity. The temperature differences across each interface as well as
across the sample were measured using thermocouples at regular
intervals until steady state was achieved. Using the Fourier law
of heat conduction, the required conductivity was calculated.
THEORY
When a temperature gradient exists in a body, experi-
ence shows us that there is an energy transfer from the high-
temperature region to the low-temperature region. The energy
thus transferred is by the process of conduction and the heat
transfer rate per unit area is proportional to the normal tempera-
ture gradient.

INTRODUCTION
Heat transfer can be defined as the process by which there is
a transfer of energy from one location to other, provided a proper
temperature gradient exists. This transfer can be caused by the
various mechanisms like conduction, convection and radiation.
Conduction can be defined as the transfer of energy from a
higher temperature region to lower temperature region by means
of the free electron movement and also the lattice vibration. The
heat transfer rate for steady one dimensional transfer can be given
as q = −KA(OT ), where k(W /mK) is called the thermal con-
ductivity of the material. Thermal conductivity can be defined
as the ability of the material to conduct heat and its reciprocal is
called thermal resistivity. Materials having a higher k value will
have higher heat transfer rate than the materials having a lower
k value. Thus the materials of higher k values can be used as
heat sink application and materials of lower k value can be used
for the insulation applications. Generally, k value of the mate-
rial depends on the temperature. Study of thermal conductivity
finds an application in various fields like material science, insu-
lation, high operating temperature conditions etc.. This report
deals with the systematic way to find the thermal conductivity of
the aluminum specimen and also the thermal contact resistance
q ∂T
∝
A ∂x
When the proportionality constant is inserted, we get
∂T
q = −kA
∂x
where q is the heat transfer rate and ∂T
∂x is the temperature gradi-
ent in the direction of heat flow. The positive constant k is called
the thermal conductivity of the material. The minus indicates that
the flow is downhill. This equation is known as Fourier’s law of
heat conduction.
a) Determining the overall heat transfer coefficient
The heated, intermediate and cooled sections are clamped
tightly together, so that the end faces are in good thermal
contact, and create a composite bar with a Aluminium section
sandwiched between two Brass sections as shown below.
For continuity, the steady heat flow through the successive

1
Figure 1. TEMPERATURE DISTRIBUTION ALONG THE LENGTH OF
(=0.03m)
THE SPECIMEN
Therefore,

pic_1.png Q∆xint
kint =
Aint (Thot f ace − Tcold f ace )

Thermocouples T3 and T6 are located 7.5 mm from the end face

compared with a distance of 15mm between adjacent thermocou-
ples (half the distance), therefore:
pic_2.png In the case of heated section the temperature of the end face (hot
face) will be lower than T3 and can be calculated as follows:

(T2 − T3 )
Figure 2. TEMPERATURE DISTRIBUTION ACROSS THE INSULATOR Thot f ace = T3 −
2

pic_3.png Similarly

T6 − T7
Tcold f ace = T6 +
2

sections must be the same so Fourier’s Law can be applied to the c) Determining the thermal conductivity of an insulator
three sections as follows: Material such as paper and cork have very low values of ther-
mal conductivity which means only a small amount of heat will
pass through the material even though a high temperature differ-
Q khot ∆Thot kint ∆Tint kcold ∆Tcold ence may exist across its two faces. Such materials are known
= = =
A ∆Xhot ∆Xint ∆Xcold as insulators and are practically utilized in situations where it is
required to reduce heat loss from a hot body to its surroundings.
From which it follows that: The heated and cooled sections are clamped tightly together with
the cork disk in between to create a composite bar with the insu-
  lated disk of unknown thermal conductivity sandwiched between
Q Xhot Xint Xcold two brass sections.
(T1 − T8 ) = (∆Thot + ∆Tint + ∆Tcold ) = + +
A khot kint kcold Because of the low value of k for an insulator the dimension must
be small and only a small amount of heat(low power) must flow
or through the specimen to prevent a large temperature difference
which will trip the thermostat.
 
Q 1 Xhot Xint Xcold
= U(T1 − TB )where = + + =R ∆Tins
A U khot kint kcold Q = kins where ∆Tins = (Thot f ace − Tcold f ace )
∆xint
1
where U is the overall heat transfer coefficient and U is the re- Therefore
sistance to heat flow R.
q
kins =
b) Determining the thermal conductivity of the metal Ains (Thot f ace − Tcold f ace )
The heated, intermediate and cooled sections are clamped
tightly together so that the end faces are in full thermal contact, In the case of heated section the temperature of end face (hot
and create a composite bar with a metal specimen of unknown face) will be lower than T3 and can be calculated as follows
thermal conductivity sandwiched between two brass sections.
From Fourier’s law Q = kint Aint ∆T ∆xint where ∆Tint = (Thot f ace −
int
(T2 − T3 )
Tcold f ace ) and ∆xint is the length of the intermediate specimen Thot f ace = T3 −
2
2
In the case of cooled section the temperature of end face (cold • Same procedure was repeated by changing voltage value
face) will be lower than T6 and can be calculated as follows (15V).

(T6 − T7 )
Tcold f ace = T6 +
2 OBSERVATIONS

APPARATUS Table 1. OBSERVATION TABLE

Aluminium heat conducting specimen
Time (mins) T1 oC T2 oC T3 oC T6 oC T7 oC T8 oC
A multi-section bar for the examination of linear conduction.
Insulator material 0 40.2 38.1 36.2 32.6 31.4 30.9
The aluminium specimen is sandwiched between two sec-
tions which are covered by insulator material and are 3 46.1 43.4 40.9 35.5 33.5 32.4
clamped tightly. 6 48.9 46.2 43.6 38 36.1 35.2
Electrical console
Provides electrical power for heaters in the specimens and 9 52.2 49.3 46.7 41.4 39.4 38.6
digital readout of the temperature at any of the selected 12 54.3 51.6 49 43.6 41.7 40.7
points along the heat-conducting paths.
Thermocouples 15 56.2 53.4 50.7 44.5 42.2 40.9
Three thermocouples are located on each brass sections with 18 57.3 54.3 51.4 44.6 42 40.4
a distance of 15mm between adjacent thermocouples.
Heat Transfer Service device 21 57.4 54.4 51.4 44.2 41.5 39.5
Thermocouples are connected to the Heat Transfer Service 30 57.5 54.4 51.6 42.8 40.3 38.5
device which displays the temperature.
Flow sensor 33 58 55.2 51.8 42.6 40.1 38.4
Cold water is supplied in pipe which passes through a 35 58.5 55.9 53.4 42.3 39.7 38.1
solenoid valve and a flow sensor. Flow sensor is used to
measure the flow rate. 38 58.2 55.2 52 43.3 40.5 38.5
Heat sink compound
41 58.1 55 51.9 43.2 40.4 38.4
Heat sink compound is applied between the joints to ensure
proper conduction between them.

PROCEDURE
• All the thermostat cables were attached to the Heat Transfer
service unit and to the temprature measuring points on the
sample.
• Aluminium specimen was fixed in between the heat source
and sink.
• Cold water supply for cooling the heat sink was turned on
and auxiliary control was used to adjust the flow rate as re-
quired.
• Voltage(10V for first case), current and water flow rate was-
set.
• Temperature values of thermocouples(T1,T2,T3,T6,T7,T8)
are recorded for every 3 minutes.
• . The graph of temperatures is plotted to find out the steady
state temperatures.
• Temperature values of hot and cold surfaces was found using
steady state temperature values.
• Thermal conductivity value of aluminium and overall heat
transfer coefficient of composite bar was calculated.
RESULTS
Following results were observed after conducting the exper-
iment.
1. The steady state assumption for specimen was verified and
found to hold after a sufficient time interval.
2. Thermal conductivity of aluminium alloy was found to be
111.6019 W /m − K with a deviation of 38% from the actual
value 180 W /m − K.
SOURCES OF ERROR
1. Heat loss through nylon insulation.
2. Fluctuations in the water flow rate.
3. There may have been fluctuations in the supply voltage
4. Convection losses may have caused faulty results.
5. Thermocouple error may have been present.
6. Thermal contact resistance between aluminium and brass
section both on upper and lower side.

3
 Figure 3. TIME vs TEMPERATURE PLOT
Taking the observation at time t = 41 minutes (from 3 and 4):
Thot f ace = 50.35 oC Tcold f ace = 44.6 oC Using 5:

∆T = (50.35 − 44.6) = 5.75 oC

Now we finally use 6 to calculate the thermal conductivity of the

intermediate material:

10.5 × 0.03 W
kint = −4
( )
4.909 × 10 × (50.35 − 44.6) m − K

Thus,

W
kint = 111.60
m−K
REFERENCES
[1] http://en.wikipedia.org/wiki/
APPENDIX B: Error Analysis
Thermal conduction
Individual errors in x,d,∆T,V and I would contribute in the
[2] Yunus A. Cengel, Af- shin J. Ghajar, Heat and Mass trans-
net error while calculating the thermal conductivity k.
fer, McGraw Hill Education (India) Private Limited.
[3] Heat Transfer Lab manual, Aerospace Engineering Depart-
ment, IIST ∂k Q̇
ω1 = δx = × 0.0001 = 0.372
∂x A∆T
APPENDIX A: Sample Calculations
∂k −8Q̇x
ω2 = δd = 3 × 0.0001 = −0.893
∂d πd ∆T
Q̇ = V I W (1)
A = πr2 m2 (2)
T2 − T3 o ∂k −Q̇x
Thot f ace = T3 − ( C) (3) ω3 = δ∆T = × 0.1 = −1.941
2 ∂∆T A∆T 2
T6 − T7 o
Tcold f ace = T6 + ( C) (4)
2
∆Tint = (Thot f ace − Tcold f ace ) (oC) (5) ω4 =
∂k
δV =
Ix
× 0.1 = 1.116
Qxint ∂V A∆T
kint = (6)
Aint (Thot f ace − Tcold f ace )
∂k Vx
ω5 = δI = × 0.01 = 1.063
∂I A∆T
V = 10V
I = 1.05 A q
ωtotal = (0.372)2 + (−0.893)2 + (−1.941)2 + (1.116)2 + (1.063)2

From 1:
Q̇ = 10 × 1.05 = 10.5W Using 2: = 2.66

0.0252 2 2.66
A = π× m = 4.909 × 10−4 m2 %Error = × 100 = 2.38%
4 111.60

4
APPENDIX C: Proposed Experiment
Measurement of Thermal Contact Resistance
In the analysis of the heat conduction through two bodies,
we assume that the contact between them is perfect, and that no
temperature drop appears across the interface. This is an ideal
case that occurs when the surfaces are assumed to be entirely
smooth without any irregularities. However, in practice there are
always voids due to the irregularity formation and these voids are
filled by air. Thus the interface offers resistance to heat transfer
and such a resistance per unit area is called thermal contact re-
sistance, Rc .
Therefore, the heat transfer through two bodies pressed together
is actually due to the point to point contact of each of the crusts
of the irregularities, and also the heat transfer through the voids
in the non contact areas which is actually a major contributor.

Q = Qcontact + Qgap Figure 4. MEASURING THERMAL CONTACT RESISTANCE

Qgap = hc A ∆Tinter f ace

Thermal contact resistance,

∆Tinter f ace
Rc =
Q/A

The value of thermal contact resistance depends on the surface

roughness and the material properties as well as the temperature
and pressure at the interface and the type of fluid trapped at the
interface. Thus, to minimize this resistance, a thermally conduct-
ing liquid called a thermal grease such as silicon oil is applied on
the surfaces before they are pressed together. Another method is
to replace the air by better conducting gases such as helium or
hydrogen (for specific applications that require minimum ther-
mal resistance).
It is because of the presence of thermal contact resistance that
the thermocouples in our experiment are attached a little away
from the interface. The air gaps cause a non-uniformity in the
flow at the interface. But as we move away from the interface,
the heat transfer becomes more uniform and can be considered
as one-dimension heat flow.
Various loses do occur other than due to contact resistance. There
could be radiations loses, as well as convection loses if the bodies
are not fixed tightly.