Novel Stacked Wire Mesh Compact Heat Exchangers Produced Using Cold Spray

This study examines the feasibility of using the pulsed gas dynamic spraying (PGDS) process to deposit metal powder on the outer surfaces of metal wire mesh wafers for use as high-performance compact heat exchangers. Plain-square weave woven mesh produced from stainless steel wires were stacked and sintered to form wire mesh bricks, which were then cut into wafers. The outer surfaces of the wafers were sealed using the PGDS deposition technique as opposed to the more traditional brazing sheet solution. This approach provides more intimate contact between the mesh wire tips and sealed surface, thereby promoting conduction through the outer walls and improving the heat exchanger efficiency. In addition, PGDS is an attractive alternative to brazing sheets for this application because of its potential for reduced manufacturing costs. Burst and tensile tests of the PGDS coated wafers were carried out.