Enhancing Flow Condensation With 3D-Printed Refrigerant-to-Water Condenser

Abstract A flow condenser incorporating wick structures was developed to address the challenge of enhancing filmwise condensation (FWC) of low-surface-tension fluids. Water flowing through wavy channels on the opposite side of the condenser provided cooling for condensing refrigerant R134a vapor. Both the refrigerant and water sides were 3D printed as a single unit using a high-thermal-conductivity copper alloy (GRCop-42). The condenser demonstrated the ability to maintain an internal pressure exceeding 600 PSI over an extended period. Condensation tests were conducted under different inlet water temperatures and refrigerant flow rates. For comparison, the performance of the wicked condenser was benchmarked against a plain condenser with no features on its refrigerant side, while maintaining identical water side. Results showed significant enhancement in FWC with the wicked condenser, achieving 81% to 202% increase in condensation heat flux and reducing the exit vapor quality by up to 21% compared to the baseline condenser. As the proposed technology is still in its early stages, further research is needed to optimize features on both the coolant and refrigerant sides to establish the condenser as a promising solution for reducing Size, Weight, and Power (SWaP) of future cooling systems.